Additive Support Structure Pre-Consolidation for Damage-Free Removal
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Solution Overview
Problem
Existing additive manufacturing methods face difficulties in creating support structures that provide sufficient support in hard-to-reach areas of three-dimensional objects without damaging the objects during removal.
Innovation Solution
A method for additive manufacturing that forms a support structure by pre-consolidating building material layers with a lower degree of solidification, allowing it to be easily removable without damaging the object, using different exposure devices and parameters compared to the object's solidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If support structures are formed with high solidification degree to provide sufficient support, then supporting effect is improved, but removal becomes difficult and may damage the object
Solution Approach 1:
The patent applies different solidification degrees to different parts of the support structure. The portion in contact with the object is pre-consolidated with lower solidification degree for easy removal, while other portions maintain higher solidification for structural support. This local differentiation resolves the contradiction between needing strong support and easy removal.
Solution Approach 2:
The patent changes the solidification degree parameter of the building material in different regions of the support structure. By controlling exposure parameters during additive construction, the support structure achieves varying degrees of consolidation - lower where removal is needed, higher where support is critical - thus resolving the contradiction between support strength and removal ease.
2Strength
If support structures are formed in hard-to-reach areas to provide adequate support, then supporting effect is improved, but accessibility for removal becomes difficult
Solution Approach 1:
The patent applies local quality by making the object-contact portion of the support structure have lower solidification degree, which creates a fragile, easily removable state regardless of accessibility. This local property change enables removal even from hard-to-reach areas without compromising the supporting effect during construction.
Solution Approach 2:
The patent performs preliminary action by pre-consolidating the support structure with lower solidification degree during the additive construction process itself, before removal is needed. This preliminary differentiation of solidification degree ensures that even inaccessible portions can be easily removed later without requiring manual intervention in hard-to-reach areas.
3Ease of manufacture
If different exposure parameters are used for support structure and object, then removal ease is improved, but process complexity increases
Solution Approach 1:
The patent introduces dynamics by making the exposure parameters adjustable and variable during the additive construction process. The system can dynamically switch between different exposure parameter sets - one for the object and another for the support structure - allowing easy removal of supports while maintaining object integrity, thus managing the complexity through controlled variability.
Solution Approach 2:
The patent manages process complexity by systematically changing exposure parameters (such as energy density, scan speed, or layer thickness) between object construction and support structure construction. This parameter differentiation enables selective solidification degrees that facilitate easy support removal, while the systematic nature of the parameter changes keeps the process manageable rather than chaotic.
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 support structure effectively supports complex geometries without causing damage during removal, ensuring the integrity of the manufactured object.
Implementation Method 1
selective laser melting, or SLM for short... successive layer-by-layer selective exposure and the associated successive layer-by-layer selective solidification of building material layers from a building material that can be solidified by means of an energy beam
Implementation Method 2
selective laser sintering process (SLS process)... successive layer-by-layer selective exposure or pre-consolidation of the respective building material layers to be selectively solidified
Data Source
Figure 1
Figure 2~3
AI summary
Method for the additive manufacturing of a three-dimensional object (2) by successive layer-by-layer selective exposure and associated successive layer-by-layer selective solidification of building material layers from a building material (3) that can be solidified by means of an energy beam (4), wherein, within the framework of the additive manufacturing of the additively manufactured three-dimensional object (2), a support structure (11) immediately surrounding the additively manufactured or manufactured three-dimensional object (2) is formed by successive layer-by-layer selective exposure and associated successive layer-by-layer selective pre-solidification of building material layers from the building material (3) that can be solidified by means of the energy beam (4).