Additive Manufacturing Support Shape Selection for Deformation Control
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Solution Overview
Problem
In powder additive manufacturing of metal materials, the cost of removing supports is high due to the difficulty in forming supports and manufactured objects from different materials, and small supports increase the likelihood of deformation from stress and thermal contraction, leading to manufacturing failures and increased costs when multiple objects are produced simultaneously.
Innovation Solution
An input data creation device that calculates mechanical quantities and determines optimized support shapes with sufficient mechanical strength and ease of removal, using a mechanical quantity calculation unit and support shape determination unit to select support shapes with minimal removal time and stress resistance, and optionally utilizing databases for pre-stored information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If small supports are used to reduce material consumption and ease removal, then removal time and cost decrease, but the likelihood of deformation from stress and thermal contraction increases
Solution Approach 1:
The patent applies preliminary action by calculating mechanical quantities (stress, force) on supports before manufacturing begins, and determining appropriate support shapes in advance based on predicted thermal contraction and deformation risks. This allows optimization of support design prior to production, ensuring they are sufficiently robust to prevent manufacturing failures while minimizing excess material.
Solution Approach 2:
The patent utilizes parameter changes by varying support shape parameters (cross-sectional area, length, positioning) based on calculated mechanical quantities and predicted deformation characteristics. Different support shapes are selected or designed to match specific stress conditions and thermal contraction patterns of different manufactured objects, achieving optimal balance between robustness and removability.
2Ease of manufacture
If support shapes are optimized for ease of removal, then removal cost decreases, but mechanical strength and stress resistance may be insufficient
Solution Approach 1:
The patent applies parameter changes by systematically varying support geometric parameters (cross-sectional dimensions, length, shape configuration) and evaluating their impact on both mechanical strength and removability. Support shapes are optimized by adjusting these parameters to achieve sufficient stress resistance while maintaining ease of removal characteristics.
Solution Approach 2:
The patent uses preliminary action by pre-calculating mechanical quantities and predicting deformation behavior for different support shapes before manufacturing. This allows selection of support configurations that inherently provide adequate strength while being easy to remove, rather than relying on post-manufacturing trial and error.
3Reliability
If robust supports are used to prevent deformation, then manufacturing reliability increases, but removal time and cost increase
Solution Approach 1:
The patent applies parameter changes by optimizing support geometric parameters to achieve the minimum necessary robustness for preventing deformation. Rather than using uniformly robust supports, the system calculates specific mechanical quantity thresholds and selects support parameters that meet these thresholds with minimal excess, reducing removal time while maintaining reliability.
Solution Approach 2:
The patent applies local quality by providing enhanced support robustness only in regions where mechanical quantities indicate high stress or deformation risk, while using simpler, easier-to-remove supports in low-risk regions. This localized optimization prevents unnecessary removal time for supports that don't require high robustness.
4Reliability
If support shapes are not optimized, then manufacturing failures occur due to deformation, but optimizing support shapes increases device complexity
Solution Approach 1:
The patent applies self-service by implementing an automated system that performs mechanical quantity calculations, deformation predictions, and support shape optimizations without requiring manual intervention. The system automatically processes manufacturing data, calculates stresses and thermal contraction, and determines optimal support configurations, reducing the perceived complexity for users while achieving high reliability.
Solution Approach 2:
The patent uses feedback by incorporating deformation prediction based on thermal contraction characteristics and mechanical quantity calculations into the support design process. The system evaluates potential support shapes against predicted deformation outcomes and iteratively optimizes support parameters to prevent manufacturing failures, creating a closed-loop optimization process.
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 device effectively designs and provides supports that prevent manufacturing failures while minimizing removal time and costs, enhancing the efficiency of powder additive manufacturing by ensuring the mechanical strength of supports and reducing deformation risks.
Implementation Method 1
a method of manufacturing (for example, a powder bed fusion bonding method or a directional energy deposition method) by melting and bonding a powder layer of the material (for example, a thickness of several tens to several hundreds of μm) by a heat source (for example, laser light or electron beam)
Implementation Method 2
deformation due to own weight or thermal contraction is likely to occur due to weak support from below
Data Source
AI summary
An input data creation device for powder additive manufacturing that can design and provide an appropriate support that avoids manufacturing failure. The device creates input data of a model in which a support is provided to a manufacturing designed object in powder additive manufacturing. The device includes a mechanical quantity calculation unit including a mechanism configured to calculate a mechanical quantity generated on a surface to which the support is provided in the manufacturing designed object; and a support shape determination unit including a mechanism configured to determine, based on information on a plurality of types of support shapes, information on an allowable mechanical quantity defined for each support shape, and a mechanical quantity calculated by the mechanical quantity calculation unit, an optimized support shape having an allowable mechanical quantity equal to or greater than the calculated mechanical quantity from among the plurality of types of support shapes.