Lattice Support Structures for Powder Bed Fusion Residual Stress
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Solution Overview
Problem
Additive manufacturing systems face challenges with support structures in powder bed fusion, as larger structures can cause warping or breakage due to residual stresses and heat conduction, while smaller structures lack holding strength, leading to potential system malfunctions.
Innovation Solution
The method involves generating a lattice configuration support structure using 3-D imaging software, which is then melted or fused with the component, and later removed via chemical etching or other means, providing a secure connection and efficient heat dissipation without excessive warping or breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If larger support structures are provided to supply increased holding strength, then the holding strength between component and support structure is improved, but the build platform may warp due to significant heat conduction and the support structure requires more time and energy to remove
Solution Approach 1:
The support structure is divided into multiple lattice cells arranged in an array, where each cell provides localized support while distributing thermal and mechanical loads. This segmentation allows the support structure to maintain holding strength through collective support while reducing heat conduction to the build platform and minimizing warping risks.
2Object-affected harmful factors
If smaller support structures are used to reduce heat conduction and removal time, then the heat conduction to build platform and removal time are reduced, but the holding strength decreases and the component may break away from the support structure
Solution Approach 1:
The lattice structure provides locally optimized support properties where the cellular geometry and material distribution are tailored to achieve the desired balance between holding strength and thermal management. The local cell structures provide sufficient support at component-critical locations while maintaining overall thermal efficiency.
3Stability of the object's composition
If larger support structures are used to ensure component stability, then the component stability is improved, but the residual stresses cause the component or build platform to warp or break away
Solution Approach 1:
The lattice configuration segments the support structure into multiple small cells that distribute residual stresses throughout the structure, preventing stress concentration that would lead to warping or breakage. This segmented approach maintains component stability while managing thermal stress effectively.
4Area of stationary object
If the support structure is made larger to provide increased contact surface area, then the contact surface area between component and support structure is improved, but the build platform warps due to significant heat conduction
Solution Approach 1:
The lattice structure functions as a porous support structure that provides adequate contact surface area through its cellular geometry while maintaining low thermal mass and reduced heat conduction to the build platform. The porous configuration allows sufficient mechanical contact without the heat transfer problems of solid structures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the stability and manufacturability of components by minimizing residual stresses and heat conduction issues, allowing for successful builds without system malfunctions, while optimizing post-fabrication support removal processes.
Implementation Method 1
melting or fusing, via the additive manufacturing system, layers of material to a build platform of the component so as to form the support structure and a component body
Implementation Method 2
provide a thermally conductive pathway for heat to dissipate from the component
Implementation Method 3
detaching the support structure from the component body via chemical etching
Data Source
AI summary
A method for additively manufacturing a component includes generating, via imaging software, a plurality of slices of a support structure of the component based on component geometry. The method also includes melting or fusing, via the additive manufacturing system, layers of material to a build platform of the component so as to form the support structure according to the plurality of slices. The support structure includes a lattice configuration having of a plurality of support members arranged together to form a plurality of cells. Further, the method includes melting or fusing, via the additive manufacturing system, a component body to the support structure. After the component body solidifies, the method includes removing all of the support structure from the component body to form the component.