Prefabricated Braces for Additive Manufacturing Lateral Force Mitigation
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Solution Overview
Problem
Conventional direct metal laser sintering (DMLS) systems face issues with deformation or breakage of components with low aspect ratios due to lateral forces generated by the recoater, and existing solutions for reducing deformation are resource-intensive or limited in applicability.
Innovation Solution
The system employs prefabricated braces located adjacent to the component's periphery, extending from the stage toward the recoater, which are designed to slide through openings in the stage and maintain a gap from the component to mitigate lateral forces without interfering with the manufacturing process, and can be reused.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sacrificial support structure is printed simultaneously with the component, then component deformation and breakage are reduced, but material consumption and manufacturing time increase
Solution Approach 1:
The brace is fabricated before the additive manufacturing process begins and positioned in advance on the stage. This preliminary placement provides immediate structural support during layer deposition without requiring simultaneous printing of sacrificial support structures, thereby reducing material consumption while maintaining component integrity
Solution Approach 2:
The support function is extracted from the component design itself and separated into a distinct, reusable brace element. This allows the support structure to be independently fabricated and reused across multiple manufacturing cycles, eliminating the need to print disposable support material with each component
2Reliability
If sacrificial support structure is printed simultaneously with the component, then component deformation and breakage are reduced, but manufacturing time increases
Solution Approach 1:
The brace is prepared and positioned on the stage before the additive manufacturing process starts. This advance preparation eliminates the need to print support structures during each manufacturing cycle, significantly reducing manufacturing time while maintaining component integrity through continuous support
Solution Approach 2:
The brace serves as a reusable support element that can be removed and reused across multiple manufacturing cycles. This recovery and reuse capability eliminates the time penalty of printing disposable support structures with each component, maintaining reliability while improving manufacturing efficiency
3Manufacturing precision
If prefabricated support piece is inserted into interior cavity, then overhang support is improved, but lateral strength increase is limited
Solution Approach 1:
The brace extends vertically from the stage upward through the build chamber, providing support in the vertical dimension rather than only within the horizontal cavity. This vertical extension allows the brace to counteract lateral forces from the recoater more effectively, increasing lateral strength while maintaining overhang support capabilities
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 effectively reduces component deformation and breakage, enhances manufacturing accuracy, and decreases resource consumption by minimizing the need for additional support structures, thereby improving the efficiency and profitability of the additive manufacturing process.
Implementation Method 1
The DMLS technique uses a laser to direct a high-energy beam into a powdered metal medium at precise locations corresponding to features and dimensions of the component to be manufactured. As the energy beam contacts the powdered metal, the powdered metal is caused to melt and weld together
Implementation Method 2
the recoater exerts lateral forces on the component due to friction generated within the powdered metal
Data Source
AI summary
A system is disclosed for use in manufacturing a component. The system may have a build chamber, a stage movable within the build chamber, and a recoater configured to deposit a layer of powdered material on top of the stage. The system may also have an energy source configured to direct a beam onto the layer of powdered material in a pattern corresponding to a shape of the component, and a brace fabricated before manufacturing of the component. The brace may be located adjacent a periphery of the component and extend from the stage toward the recoater.