Support structures in additive manufacturing
AssigneeDivergent Technologies, Inc.
InventorsEahab Nagi El Naga, John Russell Bucknell, Chor Yen Yap, Broc William TenHouten, Antonio Bernerd Martinez
Life of this patent
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Abstract
Systems and methods of support structures in powder-bed fusion (PBF) are provided. Support structures can be formed of bound powder, which can be, for example, compacted powder, compacted and sintered powder, powder with a binding agent applied, etc. Support structures can be formed of non-powder support material, such as a foam. Support structures can be formed to include resonant structures that can be removed by applying a resonance frequency. Support structures can be formed to include structures configured to melt when electrical current is applied for easy removal.
Claims9
An apparatus for powder-bed fusion, comprising:
- a depositor configured to deposit a plurality of layers of a powder material, the depositor configured to move across a work area of a powder bed to deposit each of the plurality of layers;
- an energy beam source that generates an energy beam;
- a heater press that at least partially sinters and compacts the powder material in a first area in a first one of the layers;
- and
- a deflector that applies the energy beam to fuse the powder material in a second area in a second one of the layers, wherein the first area is underneath at least a portion of an overhang area of a build piece and above a region of unfused and unbound powder.
An apparatus for powder-bed fusion, comprising:
- a depositor configured to deposit a plurality of layers of a powder material, the depositor configured to move across a work area of a powder bed to deposit each of the plurality of layers;
- an energy beam source that generates an energy beam;
- a heater press that at least partially sinters and compacts the powder material in a first area in a first one of the layers;
- a deflector that applies the energy beam to fuse the powder material in a second area in a second one of the layers, wherein the first area is underneath at least a portion of an overhang area of a build piece and above a region of unfused and unbound powder;
- and
- a support structure, coupled to the powder material in the first area in the first one of the layers.
An apparatus for powder-bed fusion, comprising:
- a depositor configured to deposit a plurality of layers of a powder material, the depositor configured to move across a work area of a powder bed to deposit each of the plurality of layers;
- an energy beam source that generates an energy beam;
- a heater press that at least partially sinters the powder material in a first area in a first one of the layers, and the heater press is configured to compact the powder material in the first area;
- and
- a deflector that applies the energy beam to fuse the powder material in a second area in a second one of the layers, wherein the first area is underneath at least a portion of an overhang area of a build piece and above a region of unfused and unbound powder, and wherein the at least partially sintered powder material is further under at least a portion of an overhang of another component.
Dependencies are inferred from the claim text.