3D Printed Support Structures With Interface Agent
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Solution Overview
Problem
In 3D printing, especially in powder-bed techniques, support structures added to metal objects during the sintering phase often cause deformation and require manual removal, which is cumbersome due to their uniform composition with the object, leading to additional processing steps and potential damage.
Innovation Solution
A system and method that use a software application to analyze the object model and calculate the position, geometry, and number of support structures, incorporating an interface agent to create a weak interface between the support structures and the object, allowing for predetermined force removal after sintering, facilitating easier and automated detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If support structures are made from the same build material as the object, then they provide adequate structural support during sintering, but they become difficult to remove and require additional manual processing
Solution Approach 1:
The interface between the support structure and object is given a different material composition (interface agent with different melting point) than the rest of the support structure and object, creating a localized weak point that facilitates selective removal while maintaining overall structural integrity during sintering
Solution Approach 2:
The interface agent has different thermal properties (melting point) compared to the build material, allowing the interface to soften and become removable at temperatures below the sintering temperature, enabling easy separation after the sintering process
2Loss of substance
If manual removal of support structures is used, then complete removal can be achieved, but it is cumbersome and time-consuming
Solution Approach 1:
The interface agent automatically softens at a predetermined temperature during or after sintering, enabling the support structures to be removed without requiring manual intervention, thus eliminating time-consuming manual processing while ensuring complete removal
3Manufacturing precision
If support structures are added to prevent deformation during sintering, then manufacturing precision is improved, but additional processing steps are required for removal
Solution Approach 1:
The interface region is differentiated from the rest of the support structure through the use of interface agent, creating a localized weak interface that allows automatic removal without manual intervention, thus eliminating additional processing steps while maintaining manufacturing precision during sintering
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
Enables cleaner and more efficient removal of support structures with a predetermined force, reducing manual processing and potential damage to the object, especially beneficial for larger volumes and automated production.
Implementation Method 1
a first portion of the layer is bound by the binder agent and a second portion of the layer is not bound by the binder agent
Implementation Method 2
the green part is heated to cause the metal build material to sinter and fuse together
Data Source
AI summary
According to one example there is provided a non-transitory computer readable storage medium comprising instructions that, when executed by a processor, cause the processor to: obtain an object model; analyse the object model; obtain characteristics of an interface agent; generate a modified object model comprising a support structure and an interface between the support structure and the object, the interface being such that after generation of a 3D printed green part and after sintering thereof, the support structure may be released with a predetermined force; and controlling a 3D printer to generate a 3D printed green part based on the modified object model.