Topology-Optimized Support Structures for Sintering Distortion

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Solution Overview

Problem

Conventional methods for designing support structures for parts with complex geometries in additive manufacturing are inefficient, time-consuming, and lack automation, leading to gravity-based deformations and distortions during the sintering phase, particularly in binder jet processes, where achieving required dimensional tolerances is challenging.

Innovation Solution

An automated method using iterative topology optimization to generate optimized support structures that counteract predicted gravity-based distortions, involving the definition of a design space and execution of a topology optimization process to minimize support material volume while ensuring part tolerance compliance, which is then transmitted to an AM controller for fabrication.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual methods are used to design support structures, then the designer can rely on experience and knowledge, but the process is inefficient, time-consuming, and not repeatable

Engineering Contradiction:

Improvedesign repeatabilityVSAvoiddesign efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces manual mechanical design processes with an automated computational system that uses finite element analysis and topology optimization algorithms. The processor-based system automatically generates support structures based on part geometry and sintering conditions, eliminating reliance on designer experience while improving repeatability and efficiency simultaneously.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If conventional support design methods are used, then simple geometries can be supported, but complex geometries experience large distortions during sintering

Engineering Contradiction:

Improvegeometry complexity handlingVSAvoiddimensional tolerance

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent performs preliminary finite element analysis and topology optimization before manufacturing to predict and compensate for sintering distortions. The system calculates expected shrinkage and warpage, then designs support structures that counteract these predicted deformations, enabling complex geometries to maintain dimensional tolerances throughout the sintering process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent optimizes support structure parameters such as material distribution, thickness, and positioning based on finite element analysis results. The topology optimization process adjusts these parameters to minimize predicted sintering distortions while maintaining support effectiveness, allowing complex geometries to be manufactured within tolerance.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If support material volume is increased to reduce distortions, then part stability improves, but manufacturing time and material costs increase

Engineering Contradiction:

Improvepart stability during sinteringVSAvoidmanufacturing time

Core Design Contradiction:

Stability of the object's compositionVSLoss of time

Solution Approach 1:

The patent uses topology optimization to determine the optimal material distribution in support structures, transforming continuous design space into an optimized discrete structure. This process identifies the minimum necessary support material volume and precise positioning required to stabilize the part during sintering, eliminating excessive material while maintaining stability and reducing manufacturing time.

Inventive Principle:

Principle #35Parameter changes

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

This approach enables the efficient and automated design of support structures that minimize distortions and ensure parts meet dimensional tolerances, even for complex geometries, reducing manufacturing time and costs for large and complex parts.

Implementation Method 1

counteracts predicted gravity-based distortions during the AM process

Methodology Applied

Scientific EffectGravity: Gravitation

Implementation Method 2

an additive manufacturing (AM) process

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Data Source

PatentUS11221610B1Optimized support design for sintering parts with complex features

Publication Date: 2022.01.11 GENERAL ELECTRIC CO

AI summary

A method and system to receive a specification defining a model of a part to be produced by an additive manufacturing (AM) process; define a design space to enclose the part and a support structure for the part, the support structure to support the part and printed with the part during the AM process; execute an iterative topology optimization(TO) based at least in part on the specification for the part and the defined design space, to generate a TO support structure that counteracts predicted gravity-based distortions during the AM process; save a record of the generated TO support structure; and transmit the record of the TO support structure to an AM controller, the AM controller to control an AM system to generate an instance of the part and the TO support structure based on the record.