Apparatus and methods for removable support structures in additive manufacturing

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 inductive components that can be used to facilitate removal of the support structures in the presence of an external magnetic field. Additionally, support structures can be formed to break when a fluid, such as air or water, creates a force and/or pressure at a connection point interface.

What is claimed is: 
     
         1 . An apparatus for supporting a structure in a powder bed fusion system, comprising:
 a bed into which powder layers are deposited and selectively fused to form a build piece;   a voltage source electrically coupled to a region of unfused powder under an overhang of the build piece and configured to apply a static charge to the region,   wherein the application of static charge is configured to provide a combinational force to the unfused powder in the region sufficient to support the overhang during build piece formation.   
     
     
         2 . The apparatus of  claim 1 , wherein the voltage source is configured to remove the static charge after a designated number of powder layers is selectively fused. 
     
     
         3 . The apparatus of  claim 1 , wherein an orientation of the bed is modified to reduce a volume of unfused powder necessary for use in the region during the 3-D print. 
     
     
         4 . A method for supporting a structure in a powder bed fusion system, comprising:
 depositing a plurality of powder layers in a bed;   selectively fusing the plurality of powder layers to form a build piece; and   applying a static charge to a region of unfused powder under an overhang of the build piece,   wherein the application of static charge provides a combinational force to the unfused powder in the region sufficient to support the overhang during build piece formation.   
     
     
         5 . The method of  claim 4 , further comprising removing the static charge after a designated number of powder layers is selectively fused. 
     
     
         6 . The method of  claim 4 , further comprising modifying an orientation of the bed to reduce a volume of unfused powder necessary for use in the region during the 3-D print.