Multi-Layer Sintering Support Structure with Interface Layers

Solution Overview

Problem

Conventional support structures in additive manufacturing with sinterable materials often deform or shrink mismatched to the object, and can bond with the object during sintering, leading to structural issues.

Innovation Solution

The use of alternating layers of sinterable and interface materials with different compositions, where interface layers resist bonding and have a higher sintering temperature than the sinterable layers, and a network of open passages for drainage, to create a support structure that separates from the object during sintering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional support structures are used with sinterable materials, then support structures can be fabricated to support overhangs and bridges, but the support structures deform or shrink in patterns that do not match the supported object and bond with the object during sintering

Engineering Contradiction:

Improveability to fabricate complex geometriesVSAvoidshape retention accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The support structure is divided into multiple alternating layers of sinterable material and interface material. Each interface layer acts as a independent segment that resists sintering, creating discrete zones of differential shrinkage behavior that prevent bonding while maintaining overall support function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different materials are used at different locations within the support structure. The interface layers use material with higher sintering temperature and different shrinkage characteristics than the sinterable layers, creating local zones that prevent bonding while other zones maintain structural support.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If conventional support structures are used with sinterable materials, then support structures can be fabricated to support overhangs and bridges, but the support structures bond with the object during sintering to form a single inseparable structure

Engineering Contradiction:

Improveability to fabricate complex geometriesVSAvoidseparation ease

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The support structure is divided into multiple alternating layers of sinterable material and interface material. Each interface layer acts as a independent segment that resists sintering, creating discrete zones of differential shrinkage behavior that prevent bonding while maintaining overall support function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The interface layer material acts as an intermediary substance between the sinterable support layers and the object. This intermediary material resists sintering and bonding, allowing the support structure to be fabricated and then easily separated from the object after sintering.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If interface layers with higher sintering temperature are used, then bonding between support and object is prevented, but the device complexity increases due to multiple material types and alternating layer fabrication

Engineering Contradiction:

Improvebonding preventionVSAvoidmulti-layer structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The support structure is divided into multiple alternating layers of sinterable material and interface material. Each interface layer acts as a independent segment that resists sintering, creating discrete zones of differential shrinkage behavior that prevent bonding while maintaining overall support function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The interface layers and sinterable layers are combined into a single integrated multi-layer support structure that is fabricated together in one additive manufacturing process, then processed together during debinding and sintering, eliminating the need for separate fabrication and assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

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 allows for the fabrication of complex geometries by preventing bonding between support structures and objects during sintering, ensuring accurate shape retention and structural integrity of the final part.

Implementation Method 1

a plurality of interface layers that resists sintering at a sintering temperature for the sinterable powder of the first material

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 2

a plurality of sinterable layers having a sintering shrink rate matched to the first material

Methodology Applied

Scientific EffectSintering shrinkage: Sintering

Implementation Method 3

a network of open passages to facilitate drainage of a debinding solution from the structure

Methodology Applied

Scientific EffectGravitational drainage: Gravitation

Data Source

PatentUS11511347B2Method of forming multi-layer sintering object support structure

Publication Date: 2022.11.29 DESKTOP METAL INC

AI summary

Support substrates are used in certain additive fabrication processes to permit processing of an object. For additive fabrication processes with materials that are sintered into a final part, a multi-layer support substrate of interleaved support and interface layers is fabricated to support an object while reducing an impact of friction on shrinkage of the part during the sintering process.