Systems and methods for designing and fabricating contact-free support structures for overhang geometries of parts in powder-bed metal additive manufacturing

US9767224B2 · kind B2 · utility

Assignees

• The Board of Trustees of The University of Alabama · US
• The United States of America as represented by the Administrator of the National Aeronautics and Space Administration · US

Inventors

• Yuag-Shan Chou · Tuscaloosa, US
• Kenneth E. Cooper · Toledo, US

Key dates

• Filing date: May 13, 2014
• Grant date: Sep 19, 2017
• Expiry date: Oct 15, 2035

Classification

• Technology area (CPC Y): Emerging Cross-Sectional Technologies
• CPC primary: Y10T428/24479
• WIPO field: Materials, metallurgy
• WIPO sector: Chemistry

Abstract

Systems and methods are provided for designing and fabricating contact-free support structures for overhang geometries of parts fabricated using electron beam additive manufacturing. One or more layers of un-melted metallic powder are disposed in an elongate gap between an upper horizontal surface of the support structure and a lower surface of the overhang geometry. The powder conducts heat from the overhang geometry to the support structure. The support structure acts as a heat sink to enhance heat transfer and reduce the temperature and severe thermal gradients due to poor thermal conductivity of metallic powders underneath the overhang. Because the support structure is not connected to the part, the support structure can be removed freely without any post-processing step.