Self-Breaking Support with Fluid Passage for Additive Manufacturing
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Solution Overview
Problem
In additive manufacturing, particularly in metal powder processes, supporting non-vertical or angled surfaces is challenging due to insufficient support from non-heated metal powder, leading to shape issues under gravity, and conventional supports often interfere with fluid passage openings or require complex removal processes.
Innovation Solution
The introduction of self-breaking supports with a base and link configuration that allows fluid passage through the support, where the link is designed to break under thermal stresses during the manufacturing process, providing initial support without interfering with fluid flow and eliminating the need for post-processing removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional supports are used to support non-vertical surfaces during additive manufacturing, then the shape stability is improved, but the fluid passage functionality is blocked and post-processing removal is required
Solution Approach 1:
The support structure is divided into two functional segments: a base portion that provides stability during manufacturing and a link portion designed to break. This segmentation allows the support to fulfill its stabilizing function while enabling easy removal through controlled breakage, eliminating complex post-processing requirements.
Solution Approach 2:
The link portion of the support is designed as a temporary, disposable element that breaks and is discarded after serving its purpose during manufacturing. The base portion with fluid passages is recovered as part of the final functional object, eliminating the need for complex removal processes.
2Strength
If conventional supports are used to maintain separation between parts, then the structural integrity is improved, but the fluid flow is interfered with
Solution Approach 1:
Different portions of the support structure have different properties: the base portion is designed with fluid passages to allow fluid flow and maintain structural integrity, while the link portion is designed with reduced cross-section to enable controlled breakage. This local differentiation resolves the conflict between maintaining strength and allowing fluid flow.
Solution Approach 2:
The base portion incorporates fluid passages that create a porous-like structure, allowing fluid to flow through the support rather than being blocked by it. This maintains structural integrity while enabling fluid flow functionality.
3Adaptability or versatility
If supports are designed to break during operation, then the freedom of movement is improved, but the support may break prematurely or fail to break at the right time
Solution Approach 1:
The support structure is pre-designed with a link portion having reduced cross-sectional area, preparing it in advance to break under specific thermal stresses. This preliminary design ensures the support will break at the appropriate time during operation, providing freedom of movement when needed while maintaining reliability.
Solution Approach 2:
The link portion is designed with altered geometric parameters (reduced cross-sectional area) that change its mechanical properties. This parameter modification allows the link to break at predictable thermal stresses, providing controlled adaptability while maintaining reliable breakage timing.
4Ease of manufacture
If non-heated metal powder is used to support new layers, then the manufacturing process is simplified, but the support capability is insufficient under gravity
Solution Approach 1:
The support structure acts as an intermediary element between the non-heated metal powder and the new layer being manufactured. It provides the additional support capability needed where powder alone is insufficient, while maintaining the simplicity of the additive manufacturing process.
Solution Approach 2:
The support structure combines material properties to achieve both simplicity and support capability: it is formed from the same metal powder material as the object, maintaining process simplicity, while its engineered geometry provides enhanced support capability where 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
The self-breaking supports effectively stabilize non-vertical surfaces during manufacturing, allow fluid flow through the object, and remain stable until thermal stresses cause the link to break, eliminating the need for manual removal and ensuring the object's integrity without compromising fluid passage functionality.
Implementation Method 1
a laser beam to sinter or melt a fine metal powder
Implementation Method 2
melting entails fully melting particles of a powder to form a solid homogeneous mass
Implementation Method 3
stresses, such as thermal stress observed during operation of the metallic object, may be allowed to break the supports
Data Source
AI summary
An object includes a fluid chamber extending between a first surface and a vertically opposed second surface, the first surface including a fluid passage opening therethrough. A self-breaking support, initially configured to support the first surface, once broken creates a broken support disposed between the first surface and the vertically opposed second surface. The support includes: a base having a first end coupled to the first surface and a second opposing end. The first end of the base is wider than the second end, and a fluid passage extends through the first base for fluidly coupling the fluid chamber and the fluid passage opening in the first surface. A self-breaking link is disposed between the second opposing end of the first base and the second surface.