Thermal Dissipation Supports for Additive Manufacturing Deformation Control
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Solution Overview
Problem
Additive manufacturing processes, such as laser sintering and melting, face challenges with thermal gradients that can lead to deformation or cracking of objects due to uneven cooling and solidification, especially when melted portions are surrounded by unmelted powder, causing thermal insulation and subsequent thermal stress.
Innovation Solution
The introduction of thermal dissipation supports, which are sacrificial structures with higher thermal conductivity than unfused powder, are placed in close proximity to the object to absorb heat and regulate thermal gradients, ensuring a controlled thermal dissipation rate within specified limits, thereby preventing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If laser sintering or melting is used to fabricate complex components, then manufacturing capability and design freedom are improved, but thermal gradients cause deformation and cracking due to uneven cooling and solidification
Solution Approach 1:
A thermal dissipation support structure is introduced as an intermediary element between the built object and the build plate. This support structure has higher thermal conductivity than the unfused powder and provides a controlled thermal dissipation path, acting as a mediator to manage heat flow and prevent harmful thermal gradients in the object
Solution Approach 2:
The thermal conductivity parameter of the support structure is deliberately changed to be higher than that of the unfused powder. By modifying this physical parameter, the support structure creates a preferred thermal pathway that controls the rate of thermal dissipation, thereby managing thermal gradients and preventing deformation
2Manufacturing precision
If support structures are used to prevent deformation, then manufacturing precision is improved, but device complexity increases due to additional thermal management components
Solution Approach 1:
The thermal dissipation support structure performs multiple functions: it provides mechanical support to the built object, manages thermal gradients through controlled heat dissipation, and prevents deformation. By combining these functions into a single structure, the patent avoids the need for separate support and thermal management systems, thereby limiting the increase in process complexity
3Temperature
If thermal dissipation support structure is introduced, then thermal gradient control is improved, but manufacturing time increases due to additional fabrication steps
Solution Approach 1:
The thermal dissipation support structure is merged with the object support structure, fabricating both the object and its thermal management support in the same additive manufacturing process. This combining approach ensures thermal gradient control without requiring separate fabrication steps for thermal management components, thereby minimizing the increase in manufacturing time
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 use of thermal dissipation supports effectively manages thermal gradients, reducing the risk of deformation and cracking by maintaining a controlled thermal dissipation rate, ensuring the object meets geometric specifications and maintaining structural integrity during the additive manufacturing process.
Implementation Method 1
thermal dissipation supports, which are sacrificial structures with higher thermal conductivity than unfused powder
Data Source
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AI summary
The present disclosure generally relates to methods for additive manufacturing (AM) that utilize thermal dissipation support structures in the process of building objects, as well as novel thermal dissipation support structures to be used within these AM processes. The thermal dissipation support structures include at least one sacrificial structure that is separated from the object by a portion of unfused powder. The sacrificial structure increases a thermal dissipation rate of at least a portion of the object such that such that thermal gradients in the object remain below a specified threshold that prevents deformation of the object.