Powder Nozzle Apparatus for Overhang Support
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Solution Overview
Problem
Existing stack forming techniques struggle to create stack formations with partly protruding shapes, as they lack the capability to effectively support overhang structures during the manufacturing process.
Innovation Solution
A stack forming apparatus comprising a nozzle device, optical system, and controller that selectively supplies powdery forming materials and support materials, using laser energy to melt and stack layers, allowing for the formation of overhang shapes by incorporating a support formation that can be easily removed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If directed energy deposition is used to form layers by melting forming material with laser light, then layers can be stacked to create three-dimensional shapes, but the method cannot form partly protruding stack formations
Solution Approach 1:
The patent introduces a support material as an intermediary substance that temporarily supports overhang structures during manufacturing. This support material enables the formation of protruding shapes by providing mechanical support where the forming material would otherwise lack support, and can be removed after the forming process is complete.
Solution Approach 2:
The patent applies preliminary action by forming a support structure before depositing the forming material in overhang regions. The support material is deposited in advance to create a scaffold that enables subsequent forming material deposition in geometries that would be impossible without this preliminary structural support.
2Shape
If support structures are added to enable overhang formation, then partly protruding shapes can be created, but the support structures must be removed afterward
Solution Approach 1:
The support material is designed as a temporary, disposable component that serves its purpose during manufacturing and is then removed. It is not intended to be part of the final product, but rather a transient element that enables complex shape formation and is discarded after completing its supporting function.
Solution Approach 2:
The patent implements discarding and recovering by systematically removing the support material after the forming material has been deposited and solidified. This removal process recovers the final desired shape by eliminating the temporary support structures that are no longer needed.
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
Enables the creation of stack formations with protrusions and allows for the easy removal of support structures, enhancing manufacturing flexibility and precision in forming complex shapes.
Implementation Method 1
The optical system outputs, to the nozzle, an energy beam for melting the forming material supplied to the target
Implementation Method 2
irradiating the forming material with laser light to melt the forming material
Data Source
AI summary
A stack forming apparatus includes a nozzle device that includes a nozzle configured to supply powder to a target and to irradiate the target with an energy beam, and a supply device which selectively supplies the nozzle with a powdery forming material to form layers that form a formation, and a powdery support material to form a support layer which permits the layers formed by the forming material to be formed on the top surface thereof. The stack forming apparatus further includes an optical system which outputs the energy beam to the nozzle, and a controller which drives the nozzle and which is configured to control the supply amount of the forming material to be supplied to the nozzle and the supply amount of the support material and which stacks the layers formed by the forming material and the support layer on the target.