Additive Manufacturing Support Structure with Variable Density
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Solution Overview
Problem
In selective laser sintering, three-dimensionally shaped objects often adhere to the shaping table, making separation difficult and leading to damage, and forming thick powder layers results in warped objects due to thermal deformation, necessitating additional processing to remove the base material.
Innovation Solution
The method involves forming a support structure with a combination of low-density and high-density sintered portions, where the low-density portion is brittle and easy to separate, and the high-density portion provides mechanical strength and heat dissipation, allowing for easy detachment of the shaped object without damaging it.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a three-dimensionally shaped object is formed directly on a shaping table by selective laser sintering, then the object can be formed with good adhesion to the table, but it becomes difficult to separate the object from the shaping table without damage
Solution Approach 1:
The support structure is segmented into multiple density regions (first density region with lower density and second density region with higher density), allowing different portions to serve different functions: the lower density portion facilitates easy separation while the higher density portion provides structural support and strong adhesion to the shaping table
Solution Approach 2:
Different regions of the support structure are assigned different material densities locally. The first density region (lower density) is positioned where separation is needed, while the second density region (higher density) is positioned where structural strength and adhesion are required, optimizing both separation ease and adhesion strength in their respective locations
2Volume of moving object
If a thick powder layer is deposited on the plate to form a three-dimensionally shaped object, then the object can be formed with sufficient height, but the sintered body moves on the powder layer and warps due to thermal deformation
Solution Approach 1:
A base is formed on the plate before forming the three-dimensionally shaped object. This preliminary base provides a stable, fixed foundation that prevents the subsequent object from moving on the powder layer during sintering, thereby preventing warping while still allowing the object to achieve sufficient height
Solution Approach 2:
The support structure is divided into different density regions, with the lower density first density region facilitating controlled separation after sintering, while the higher density second density region provides the structural stability needed to prevent movement and warping during the sintering process
3Strength
If a base is formed on the plate by selective laser sintering to support the three-dimensionally shaped object, then the object can be formed with proper support, but cutting the base to separate the object requires additional time-consuming processing such as fine cutting and polishing
Solution Approach 1:
Different regions of the support structure have different densities optimized for their specific functions: the first density region (lower density) is optimized for easy separation with minimal post-processing, while the second density region (higher density) maintains sufficient structural support strength, thereby reducing the need for time-consuming fine cutting and polishing operations
Solution Approach 2:
The first density region of the support structure is designed to be easily removable with minimal processing, effectively serving as a disposable or easily discarded component that facilitates quick separation of the final object without requiring extensive post-processing 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
This approach enables the easy separation of three-dimensionally shaped objects from the support structure, reducing the need for extensive processing and minimizing damage, while maintaining the object's mechanical strength and thermal conductivity.
Implementation Method 1
selectively sintering part of a powder layer by irradiating the powder layer with laser light
Implementation Method 2
forming a three-dimensionally shaped object by repetitively performing steps of depositing raw material powder of, for example, nylon resin, ceramics, or metal layer by layer and selectively sintering part of a powder layer by irradiating the powder layer with laser light
Implementation Method 3
The low-density support portion has a lower density than a three-dimensionally shaped portion formed in the step of forming the three-dimensionally shaped object
Implementation Method 4
a sintered body is not fixed to the plate and thus moves on the powder layer and is warped due to thermal deformation
Data Source
AI summary
A method of producing a three-dimensionally shaped object includes a step of equipping an additive manufacturing apparatus with a plate, a step of forming a support portion by depositing raw material powder on the plate and radiating light, a step of forming a three-dimensionally shaped object by depositing raw material powder on the support portion and radiating light, and a step of separating the three-dimensionally shaped object from the support portion. In the step of forming the support portion, a low-density support portion and a high-density support portion are formed. The low-density support portion has a lower density than a three-dimensionally shaped portion formed in the step of forming the three-dimensionally shaped object. The high-density support portion has a higher density than the low-density support portion.