Additive Manufacturing Support Structure with Abrasive Flow Removal
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Solution Overview
Problem
Conventional support structures in powder bed additive manufacturing are difficult to remove and often cause mechanical stresses, leading to distortion and waste of components, especially in the case of protruding surfaces like those found in turbine components.
Innovation Solution
A support structure with a first domain of higher density and a second domain of lower density and greater porosity, allowing for easy removal via abrasive flow machining, which minimizes mechanical stress on the component during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional support structures are used in powder bed additive manufacturing, then protruding surfaces can be supported during manufacturing, but the support structures are difficult to remove and cause mechanical stresses leading to component distortion
Solution Approach 1:
The support structure is divided into two distinct domains: a first domain with higher density providing structural stability, and a second domain with lower density and greater porosity facilitating easy removal. This segmentation allows each domain to fulfill its specific function optimally.
Solution Approach 2:
Different regions of the support structure are assigned different material properties. The first domain (scaffold) has high density for mechanical strength, while the second domain (filler) has low density and high porosity for easy ablation. This local differentiation resolves the contradiction between stability and ease of removal.
2Strength
If conventional support structures are used, then structural support is provided, but removal requires conventional machining techniques that apply significant mechanical stresses
Solution Approach 1:
The removal process is changed from mechanical machining (which applies harmful stresses) to abrasive flow machining (which uses a flowing abrasive medium). This substitution eliminates the harmful mechanical stresses while still achieving effective support structure removal.
Solution Approach 2:
The second domain is designed with high porosity to be highly susceptible to abrasive flow machining. The porous structure allows the abrasive medium to penetrate and efficiently erode the material, enabling stress-free removal of the support structure.
3Strength
If support structures are made dense for stability, then support strength is improved, but removal becomes more difficult and time-consuming
Solution Approach 1:
The support structure is segmented into dense and porous domains, allowing the dense first domain to provide strength while the porous second domain enables rapid removal through abrasive flow machining.
Solution Approach 2:
Different density levels are assigned to different regions: the first domain has high density for strength, while the second domain has low density for fast removal. This local quality differentiation simultaneously achieves strength and high removal productivity.
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 can be efficiently removed with low stress, maintaining component integrity and stability during the manufacturing process, using a smart combined material design that provides adequate support and facilitates easy removal through flow machining techniques.
Implementation Method 1
The support structure can be removed from an adhered component, e.g. adhered during a corresponding powder bed additive manufacturing process, by abrasive flow machining
Data Source
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AI summary
The present invention relates to support structure (10) for a powder bed manufacturing process comprising a first domain (1) further comprising a first density and the second domain (2) further comprising a second density, wherein a material of the second domain (2) comprises a predetermined porosity such that the second density is lower than the first density, and wherein the first domain (1) and the second domain (2) are arranged and configured such that the support structure (10) can be removed from an adhered component (100) by abrasive flow machining.