The Penn State Research Foundation

Arizona State University

Timothy W Simpson

Abdalla R Nassar

Owen Hildreth

David Wright

Sanjay B Joshi

Xinyi Xiao

Embodiments of the systems and methods disclosed herein can related to an additive manufacturing process involving the use of an algorithm to determine the optimal build orientation of a build that will result in minimal thermal distortion during the build. The algorithm includes a momentum of inertia based objective function, wherein the output of the objective function can be used as a proxy for thermal distortion. In some embodiments, objective function can be configured as a mathematical matrix with mathematical variables modeling rotation angles of a build. The rotation angles can be in the x-, y-, and/or z-geometric planes of the build with respect to the build plate. An objective function output can be calculated for each iterative rotation. The minimum objective function output can be used as the rotation representing the orientation that would result in minimal thermal distortion.

Determining build orientation to minimize thermal distortion

Methods and systems are described for fabricating a component using 3D printing. A 3D printed piece is created including a body of the component, a support structure, and a first sacrificial interface region coupling the body of the component to the support structure. The body of the component is formed of a first metal or ceramic material and the first sacrificial interface region is formed at least partially of a second metal or ceramic material. The body of the component is then separated from the support structure by applying a chemical or electrochemical dissolution process to the 3D printed piece. Because the second metal or ceramic material is less resistant to the dissolution process than the first metal or ceramic material, the first sacrificial interface region at least partially dissolves, thereby separating the body of the metal component from the support structure, without dissolving the body of the component.

Fabricating metal or ceramic components using 3D printing with dissolvable supports of a different material

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State College, PA, United States of America

Timothy W Simpson