Additive Manufacturing Support Structure Using Semi-Sintered Particles
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Solution Overview
Problem
Current additive manufacturing processes require supports for free-hanging portions of objects during fabrication, which lead to costly post-processing steps for support removal and material recycling, and often result in remnants on critical surfaces, affecting part quality and process efficiency.
Innovation Solution
A support structure is fabricated via additive manufacturing, surrounding a portion of the object without direct attachment, using semi-sintered particles to detach the object from the support, allowing for separation without direct contact and reducing post-processing needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional supports are used during additive manufacturing to prevent deformation of free-hanging portions, then structural stability is improved, but post-processing complexity and cost increase due to support removal requirements
Solution Approach 1:
The patent introduces a build plate as an intermediary substrate that provides structural support during the additive manufacturing process. The build plate acts as a mediator between the free-hanging portions and the deformation forces, eliminating the need for traditional supports while maintaining stability. This resolves the contradiction by providing stability through the build plate rather than through removable supports, thereby reducing post-processing complexity.
2Stability of the object's composition
If attached supports are used to prevent deformation, then structural stability is improved, but manufacturing time and cost increase due to support removal and surface cleaning operations
Solution Approach 1:
The build plate serves as a permanent intermediary that eliminates the need for temporary supports. By directly anchoring free-hanging portions to the build plate, the process removes the time-consuming steps of support attachment, removal, and surface cleaning, thereby reducing total manufacturing time while maintaining structural stability throughout the process.
3Stability of the object's composition
If traditional supports are used during fabrication, then structural stability is improved, but material waste increases due to support remnants and powder recycling requirements
Solution Approach 1:
The build plate as an intermediary eliminates the need for separate support structures that would generate waste. By providing a reusable substrate that directly supports free-hanging portions, the system eliminates support remnants that would otherwise require sandblasting removal and prevents powder trapping issues, thereby reducing material waste and simplifying powder recycling operations.
4Productivity
If free-hanging portions are fabricated without supports, then post-processing operations are reduced, but deformation occurs during the manufacturing process
Solution Approach 1:
The build plate provides the necessary structural stability during manufacturing without requiring traditional supports. By anchoring free-hanging portions directly to the build plate, the system maintains stability throughout the additive manufacturing process, enabling complex geometries to be fabricated without deformation while minimizing post-processing operations and improving overall process efficiency.
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 reduces the need for traditional supports and heat sinks, improving part quality, process efficiency, and lowering costs by eliminating unnecessary post-processing steps and material recycling operations.
Implementation Method 1
Certain types of AM processes use a high energy beam, for example, an electron beam or electromagnetic radiation such as a laser beam, to sinter or melt a fine powder material
Implementation Method 2
Selective laser sintering (SLS), direct metal laser sintering (DMLS), selective laser melting (SLM)
Implementation Method 3
electron beam melting (EBM)
Implementation Method 4
a powder that is not fully sintered may attach the object to the support such that the object and the support lack any direct attachment
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
An in-process build assembly (100) includes an in-process build structure (110), a support structure (120), and semi-sintered particles. The support structure supports the in-process build structure. The support structure surrounds a cross-section of the in-process build structure without surrounding an entirety of the in-process build structure. The semi-sintered particles are located between the in-process build structure and the support structure such that there is no direct attachment of the in-process build structure to the support structure. The in-process build assembly is fabricated by an additive manufacturing process. Either one of or both the in-process build structure and the support structure are moved after the additive manufacturing process such that the cross-section of the in-process build structure is outside the support structure.