Sacrificial Support for Additive Manufacturing Composite Overhangs
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Solution Overview
Problem
Conventional additive manufacturing techniques struggle to form features like unsupported overhangs and fine structures due to lack of strength and formability in the material before rigidization, and they can damage reinforcement materials or expose them to environmental chemicals.
Innovation Solution
The use of sacrificial support materials that support continuous reinforcement materials during additive manufacturing, allowing for the formation of complex features by removing the support material after the reinforcement has been deposited and partially rigidized, and optionally coating the features with a coating that remains after the support material is removed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional additive manufacturing techniques are used to form features like unsupported overhangs and fine structures, then the manufacturing capability is limited, but the use of sacrificial support materials increases process complexity
Solution Approach 1:
A sacrificial support material is introduced as an intermediary substance that temporarily supports continuous reinforcement material during additive manufacturing. This support material enables the formation of complex features like unsupported overhangs and fine structures that would otherwise be impossible to manufacture. After the reinforcement material is deposited and rigidized, the sacrificial support material is removed, leaving the desired complex geometry without requiring complex manufacturing equipment or processes.
2Ease of manufacture
If sacrificial support materials are used to support continuous reinforcement material during additive manufacturing, then complex features can be formed, but the manufacturing time increases due to the additional steps
Solution Approach 1:
The sacrificial support material is deposited in advance before the continuous reinforcement material is added. This preliminary action provides the necessary support structure that enables the reinforcement material to be formed into complex geometries without collapse. The support material is strategically placed only where needed to provide minimal necessary support, reducing the overall amount of material and time required compared to traditional full-support approaches.
3Device complexity
If conventional techniques are used without sacrificial support materials, then the process is simpler, but the reinforcement material is damaged or exposed to environmental chemicals
Solution Approach 1:
The sacrificial support material serves as a protective intermediary between the continuous reinforcement material and the environment. During the additive manufacturing process and subsequent handling, the support material shields the vulnerable reinforcement material from environmental chemicals and physical damage. The support material is specifically positioned to cover exposed surfaces of the reinforcement material, preventing harmful interactions until the component is fully manufactured and rigidized.
Data Source
AI summary
A method may include depositing a sacrificial support material on or adjacent to a build surface. The sacrificial support material may be configured to support a continuous reinforcement material during an additive manufacturing technique. The method also may include extruding the continuous reinforcement material from an additive manufacturing device such that at least a portion of the continuous reinforcement material contacts and is supported by the sacrificial support material; and removing the sacrificial support material to result in a feature defined at least in part by the continuous reinforcement material at the absence of sacrificial support material.