Support-Free 3D Printing of Overhangs With Energy Beam Densification
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Solution Overview
Problem
Current 3D printing methods often require auxiliary supports to prevent deformation during the printing process, which increase manufacturing costs and time, and can restrict the design and formation of complex structures like cavities and overhangs.
Innovation Solution
The method involves controlling the diffusion of elements into metal alloys to achieve homogeneous crystal phases and metallurgical morphologies, and using energy beams to transform and densify layers of pre-transformed material, reducing porosity and eliminating defects like fractures, thereby minimizing the need for auxiliary supports and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If auxiliary supports are inserted to prevent deformation during 3D printing, then structural stability is improved, but manufacturing cost and time increase
Solution Approach 1:
The patent removes auxiliary supports from the printing process by controlling material properties and printing parameters to enable self-supporting structures. The system extracts the need for temporary support structures by achieving adequate structural stability through material composition control and optimized printing conditions alone.
Solution Approach 2:
The printed object supports itself during the manufacturing process through controlled material properties and structural design. The material and printing parameters are adjusted so that the object maintains its own structural integrity without requiring external auxiliary supports.
2Stability of the object's composition
If auxiliary supports are inserted to prevent deformation during 3D printing, then structural stability is improved, but device complexity increases
Solution Approach 1:
The patent eliminates the auxiliary support system by controlling material and printing parameters. This extraction of the support requirement simplifies the overall manufacturing process and reduces device complexity while maintaining structural stability through intrinsic material properties.
3Stability of the object's composition
If auxiliary supports are inserted to prevent deformation during 3D printing, then structural stability is improved, but manufacturing cost increases
Solution Approach 1:
The patent removes the need for auxiliary support materials by optimizing the primary material properties and printing parameters. This eliminates additional material costs associated with supports while achieving adequate structural stability through controlled material composition and printing conditions.
4Manufacturing precision
If diffusion process is controlled to achieve homogeneous crystal phases, then material quality is improved, but processing time increases
Solution Approach 1:
The patent controls diffusion parameters such as temperature, time, and material composition to achieve homogeneous crystal phases. By optimizing these parameters, the system attains high material quality while minimizing the time required for the diffusion process.
5Strength
If energy beam is used to densify layers and reduce porosity, then structural integrity is improved, but energy consumption increases
Solution Approach 1:
The patent optimizes energy beam parameters including power, speed, and scanning patterns to achieve effective densification and porosity reduction. By carefully controlling these parameters, the system achieves high structural integrity while minimizing energy consumption through efficient processing.
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 generation of 3D objects with reduced deformation and increased structural integrity, enabling the creation of complex geometries without auxiliary supports, thus reducing manufacturing constraints and costs.
Implementation Method 1
transforming a first pre-transformed material to a first transformed material to print a layer of hardened material
Implementation Method 2
using an energy beam to density the second transformed material to reduce or eliminate the pore
Implementation Method 3
The diffusion may comprise diffusion of at least a first element into a material deficient in that first element. The diffusion may result in a homogenous distribution of crystal phases and/or metallurgical morphologies.
Data Source
AI summary
The present disclosure provides three-dimensional (3D) printing methods, apparatuses, systems and/or software to form one or more three-dimensional objects, some of which may be complex. The three-dimensional objects may be formed by three-dimensional printing using one or more methodologies. In some embodiments, the three-dimensional object may comprise an overhang portion, such as a cavity ceiling, with diminished deformation and/or auxiliary support structures.