Additive Manufacturing Support Structure Density Gradient
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Solution Overview
Problem
Additive layer manufacturing (ALM) methods produce components with inherent residual stresses and distortion, particularly in components with overhanging features, which require support structures that consume significant material and time, and their removal is costly and limits geometry possibilities.
Innovation Solution
The method involves forming support structures with reduced density or increased porosity relative to the component, followed by a heat treatment under increased pressure to consolidate the support structures and separate them from the component, eliminating the need for manual removal and subsequent finishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If support structures are added to manage distortion and enable overhangs, then component stability and geometry capability are improved, but material usage and build time increase significantly
Solution Approach 1:
The support structure is designed with spatially varying density, having higher density at the base for stability and lower density toward the component interface to facilitate separation. This local quality variation allows the support to provide necessary mechanical stability while minimizing material usage and enabling easy detachment after manufacturing.
Solution Approach 2:
The support structure incorporates porous or hollow internal geometry, reducing its material density and mass while maintaining structural integrity. This porous design decreases material consumption and build time, and the reduced density creates a density differential that aids in automatic separation from the component after manufacturing.
2Reliability
If support structures are added to manage distortion and enable overhangs, then component stability and geometry capability are improved, but build time increases significantly
Solution Approach 1:
The support structure is designed with spatially varying density, having higher density at the base for stability and lower density toward the component interface to facilitate separation. This local quality variation allows the support to provide necessary mechanical stability while minimizing material usage and build time, and the reduced density creates a density differential that aids in automatic separation from the component after manufacturing.
Solution Approach 2:
The support structure incorporates porous or hollow internal geometry, reducing its material density and mass while maintaining structural integrity. This porous design decreases material consumption and build time, and the reduced density creates a density differential that aids in automatic separation from the component after manufacturing.
3Ease of manufacture
If manual removal of support structures is performed, then separation is achieved, but processing time and cost increase and geometry possibilities are limited
Solution Approach 1:
The support structure is designed with spatially varying density, having higher density at the base for stability and lower density toward the component interface to facilitate separation. This local quality variation allows the support to provide necessary mechanical stability while minimizing material usage and build time, and the reduced density creates a density differential that aids in automatic separation from the component after manufacturing.
Solution Approach 2:
The support structure's density parameter is varied along its length, creating a gradient from high density at the base to low density at the interface. This parameter change enables the support to provide structural stability while allowing automatic separation through density-driven detachment, eliminating manual removal operations.
4Adaptability or versatility
If support structures are used for components with overhangs, then build feasibility is improved, but surface finish quality deteriorates due to witness lines
Solution Approach 1:
The support structure is designed with spatially varying density, having higher density at the base for stability and lower density toward the component interface to facilitate separation. This local quality variation allows the support to provide necessary mechanical stability while minimizing material usage and build time, and the reduced density creates a density differential that aids in automatic separation from the component after manufacturing.
Solution Approach 2:
The support structure automatically separates from the component through density-driven detachment during or after the manufacturing process, eliminating the need for manual removal operations that create witness lines and require subsequent surface finishing operations.
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 minimizes distortion, reduces material usage, and allows for more complex geometries by automatically separating support structures from the component during heat treatment, reducing processing time and costs.
Implementation Method 1
Hot isostatic pressing (HIP) is a heat treatment in which high (up to 200 MPa) isostatic pressure is applied to a component, e.g. a component formed by an additive layer manufacturing (ALM) method, contained within an inert atmosphere in a sealed canister at a high temperature.
Implementation Method 2
subsequently carrying out a heat treatment at increased pressure on the component and support structure
Data Source
AI summary
The present disclosure relates to a method of forming a component and at least one support structure joined to the component by additive layer manufacturing, wherein the support structure has a reduced density and/or increased porosity relative to the component. The method then comprises a subsequent heat treatment step at increased pressure on the component and support structure to separate the component and at least one support structure.