Rotatable Support Structures for Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing processes face challenges in supporting complex shapes, particularly internal surfaces, where traditional support structures are difficult to remove without damaging the object due to lateral forces and geometric constraints.
Innovation Solution
The development of novel support structures that can be rotated to a second orientation to facilitate removal, featuring projections and recesses that align with the object's geometry, allowing for non-contact support during fabrication and easy extraction by aligning with an outlet, such as a ring-shaped opening, enabling the support structure to be removed through the object's cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional support structures are used during additive manufacturing, then lateral support is provided to prevent damage from recoater forces, but the support structures are difficult to remove without damaging the object due to geometric constraints
Solution Approach 1:
The support structure is divided into multiple segments including a first support portion, second support portion, and connector portion. This segmentation allows the support structure to be flexibly configured to provide lateral support during manufacturing while enabling easy removal after fabrication by disconnecting the segments from each other and from the object.
Solution Approach 2:
The support structure incorporates flexible connectors that allow dynamic adjustment and movement. The connectors enable the support structure to adapt to the object's geometry during manufacturing and facilitate removal by allowing the support portions to move relative to each other and to the object, transforming a static support into a dynamic, easily removable system.
2Manufacturing precision
If support structures are designed to conform to divergent surfaces for optimal support, then lateral support is improved, but the support structures become trapped and cannot be removed through the object's outlet
Solution Approach 1:
The support structure utilizes a multi-dimensional configuration with support portions extending in different directions and connectors providing spatial flexibility. This dimensional approach allows the support to accurately conform to divergent surfaces while maintaining extraction paths through the object's outlet by utilizing spatial freedom in multiple dimensions rather than being constrained to a single plane.
Solution Approach 2:
The support structure is designed to be nested within the object's cavity during manufacturing, with support portions positioned within the cavity and connectors allowing the support to be withdrawn through the outlet. This nesting approach enables the support to conform to internal divergent surfaces while maintaining access for removal through the object's opening.
3Stability of the object's composition
If the support structure is made rigid for stable support during fabrication, then lateral support stability is improved, but the support structure cannot be rotated or manipulated for easy removal
Solution Approach 1:
The support structure transitions from a rigid static design to a dynamic system with flexible connectors that allow movement and rotation. The connectors maintain stability during fabrication by providing firm support while enabling the support structure to be rotated and manipulated for easy removal, achieving both stability and adaptability through dynamic flexibility.
Solution Approach 2:
By dividing the support structure into segmented portions connected by flexible joints, the system achieves local rigidity for stable support where needed while maintaining overall flexibility for rotation and manipulation. The segmented design allows rigid support portions to remain stable during fabrication while the connectors enable rotational movement for easy removal.
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 method allows for the successful fabrication and removal of complex objects with divergent surfaces by providing lateral support during the additive manufacturing process, preventing damage from recoater forces and enabling efficient post-processing by allowing easy access and removal of the support structure.
Implementation Method 1
a laser beam to sinter or melt a powder material
Implementation Method 2
sintering entails fusing (agglomerating) particles of a powder at a temperature below the melting point of the powder material
Implementation Method 3
melting entails fully melting particles of a powder to form a solid homogeneous mass
Data Source
AI summary
The present disclosure generally relates to methods for additive manufacturing (AM) that utilize support structure in the process of building objects that may be removed by rotating the support structure to a second orientation before removal, as well as novel support structures to be used within these AM processes. The support structures are fabricated in a first orientation and then rotated to the second orientation. The support structures are removed by passing through an outlet of the object.