EP3999266A1

EP3999266A1 - Support structure

Info

Publication number: EP3999266A1
Application number: EP20771480.9A
Authority: EP
Inventors: Dragan MATEKALO
Original assignee: Siemens Energy Global GmbH and Co KG
Current assignee: Siemens Energy Global GmbH and Co KG
Priority date: 2019-09-10
Filing date: 2020-09-03
Publication date: 2022-05-25
Also published as: EP3791976A1; WO2021047981A1

Abstract

The present invention refers to a supported product manufactured using additive manufacturing, wherein the supported product provides an improved support structure. Furthermore, the present invention refers to a product required from such supported product. Additionally, the present invention refers to a method of manufacturing a product utilizing such supported product. Furthermore, the present invention refers to the use of such improved support structure to improve the manufacturing of such product. Additionally, the present invention refers to a computer program product utilized to perform such method. Furthermore, the present invention refers to a device for providing such computer program product.

Description

Support structure

The present invention refers to a supported product manufac tured using additive manufacturing, wherein the supported product provides an improved support structure. Furthermore, the present invention refers to a product required from such supported product. Additionally, the present invention refers to a method of manufacturing a product utilizing such sup ported product. Furthermore, the present invention refers to the use of such improved support structure to improve the manufacturing of such product. Additionally, the present in vention refers to a computer program product utilized to per form such method. Furthermore, the present invention refers to a device for providing such computer program product.

Additive manufacturing is a very flexible method of manufac turing utilizing building up a product by adding material on an existing part or right from the scratch. In recent years the possibilities significantly improved and this new method of manufacturing products has been introduced into industrial processes. Especially, the possibility to build up structures utilizing geometries not possible using conventional methods of manufacturing significantly increases the benefit provided herewith. Methods like 3D printing, for example, utilize a metal or metal composition powder being melted layer by layer to manufacture a complex 3D structure. Despite the high flex ibility provided by such method certain requirements are still to be considered. For example, it can be necessary to support a part of such product to be printed to utilize meth ods like selective laser melting (SLM). Herein, such support may be provided by a structure also printed using such addi tive manufacturing method along with the real part and later be removed. Further process steps like grinding or milling steps can be utilized in this context to provide the final product. However, such post processing steps require a sig- nificant amount of time and effort. Especially when providing test pieces or low amounts of product providing an optimized post processing procedure provide problems. Thus, it is re quired to manually remove the corresponding support structure increasing the time required and possibly leading to damages of the product resulting in the product to be manufactured again. Therefore, a solution to provide a simple removal pro cedure for a wide variety of products especially minimizing the required manual interaction would be beneficial.

These problems are solved by the products and methods as dis closed hereafter and in the claims. Further beneficial embod iments are disclosed in the dependent claims and the further description. These benefits can be used to adapt the corre sponding solution to specific needs or to solve further prob lems.

According to one aspect the present invention refers to a supported product manufactured using additive manufacturing, preferably 3D printing, wherein the supported product con tains a product and a support structure, wherein the product and the support structure are connected by means of a connec tion providing different resistances against breaking in dif ferent directions. Such connection can be provided in differ ent forms like a multitude of structures extending between the product and the support structure, a complex shaped structure like a multitude of interconnected walls providing a grid extending between the product and the support struc ture or combinations thereof. A common feature of typical em bodiments of such connection is that it is a layer between the support structure and the product and provides no homoge neous material. While the counter part of the product and the support structure attached to the connection are typically solid materials the connection typically consists of a multi tude of structures extending between the product and the sup port structure, wherein the space between these structures is either empty or filled with remains of the manufacturing pro cedure. Surprisingly, it was noted that it is possible to provide such inhomogeneous support especially providing inhomogeneous breaking behavior to significantly simplify the removal pro cedure. In fact, it becomes possible to provide support structure providing the required stability during manufactur ing and, for example, further processing steps like the re moval of powder. Simultaneously, the structure can be brittle enough to simply remove the support structure by hitting said structure on the side based on the weakness of the structure against some force applied in such direction. This allows to significantly reduce the amount of labor for providing the corresponding parts, as the required post processing to re move support structure can be reduced to an almost insignifi cant amount of work compared to conventional support struc tures.

According to a further aspect the present invention refers to a product manufactured by removing the support structure of the inventive supported product. While it is possible to re move all remains of the connection from the product it was noted that for typical applications the amount of the connec tion remaining after breaking off the support structure is very low and the product can be easily utilized without such additional process step. In such cases the product still pro vides remains of the connection during its usage.

According to a further aspect invention refers to a method of manufacturing a product containing the steps of

- manufacturing an inventive supported product using additive manufacturing, preferably 3D printing, wherein the product provides a side to be placed upon, wherein the support struc ture is located at this side to be placed upon, and

- removing the support structure from the supported product by applying a force in a direction being not perpendicular to this side to be placed upon. According to a further aspect the present invention refers to a use of the support structure for supporting a product dur ing an additive manufacturing process, wherein the support structure is adapted to be removed to provide the product, wherein the product and the support structure are connected by means of a connection providing different resistances against breaking in different directions.

According to a further aspect the present invention refers to a computer program product with program commands to perform the inventive method.

According to a further aspect the present invention refers to a device for providing an inventive computer program product, wherein the device stores the computer program product and/or provides the computer program product for further use.

To simplify understanding of the present invention it is re ferred to the detailed description hereafter and the figures attached as well as their description. Herein, the figures are to be understood being not limiting the scope of the pre sent invention, but disclosing preferred embodiments explain ing the invention further.

Fig. 1 shows a schematic side view of a guide vane of a gas turbine.

Fig. 2 shows a schematic side view of the guide vane of fig ure 1 being supported by multiple inventive support struc tures.

Fig. 3 shows a schematic side view of figure 2, wherein the arrows indicate the direction the support structure provides an increased stability.

Fig. 4 shows a cutout of the schematic side view of figure 2, wherein a part of the connection of the inventive support structure is shown. Fig. 5 shows a cutout of a schematic cross-section through a part of the connection connecting the product and the support structure.

Fig. 6 shows a cutout of a schematic cross-section showing the part of the connection as shown in figure 5 including the corresponding part of the product and the support structure.

Fig. 7 shows a schematic side view of the clamp utilized in a gas turbine supported by an inventive support structure and connected by a structure of the connection comparable to the part of the connection shown in figure 5.

Fig. 8 shows a cutout of the schematic side view of the sup ported product as shown in figure 7, wherein the end part of the support structure supporting the clamp is shown.

According to one aspect the present invention refers to a supported product as specified above.

While it is possible to provide a single support structure to support the whole product for typical embodiments, it was noted that utilizing a multitude of support structures is typically beneficial. According to further embodiments it is preferred that the supported product contains at least two support structures. For example, this allows to minimize the material required and utilize parts of the product to stabi lize the supported product reducing the overall amount of ma terial required to provide the supported product.

During common additive manufacturing methods the manufactur ing method includes building the supported product starting from a base layer building upon that base layer the remaining supported product. Such base layer, thus, provides a side the supported product is to be placed upon. Also, it can be bene ficial to include such support on the side to place the fi nally supported product upon such side for later processing steps. Herein, it was noted that it is beneficial to design the stability of the support structure in correlation to such side it is planned to place the supported product upon. Ac cording to further embodiments it is preferred that the sup ported product provides a side to be placed upon, wherein the connection provides a higher resistance against breaking per pendicular to the side to be placed upon than parallel to a plane along the side to be placed upon. It was noted, that such design significantly simplifies the post processing for typical cases.

Additive manufacturing methods are well established despite being relatively new. Especially additive manufacturing meth ods like 3D printing became topic for industrial applications in the past years and show a big potential to complement or replace existing conventional methods of manufacturing. The additive manufacturing methods are characterized by that a material is applied without some limiting element like some casting mold to build up the product. Examples of especially useful additive manufacturing methods are selective laser melting, electron beam melting and binder jetting. Such meth ods either build up a product utilizing a powder that typi cally is removed in a later step like it is done for binder jetting. Very useful for the current application are 3D printing additive manufacturing methods like selective laser melting and electron beam melting building up the product from a powder, wherein the powder is melted layer by layer.

By repeating this melting process for each layer of the prod uct the 3-dimensional element is provided.

To provide such products a number of additive manufacturing methods have been established. Examples are selective laser melting (SLM) or electron beam melting (EBM). According to further embodiments it is preferred that the supported prod uct has been manufactured using a metal powder or metal com position powder. Herein, corresponding manufacturing methods allow to easily realize the inventive support structures and simultaneously benefit greatly from the inventive design, as such support structures allow to realize new designs for in dustrial purposes providing a significantly simplified post processing.

The additive manufacturing allows to flexibly design the properties of the supported product as required selecting the design according to certain frame conditions. Thus, the in ventive supported product and method can be easily adapted to a plurality of possible products. According to further embod iments it is preferred that the force required for breaking off the support structure applied perpendicular to the side to be placed upon is at least 3 times, more preferred at least 5 times, even more preferred at least 15 times, the force required for breaking off the support structure paral lel to a plane along the side to be placed upon. Adapting it according to such requirement further simplifies the labor required to provide the inventive support structure for arbi trary products.

Surprisingly, it was noted that it was even possible to real ize the inventive design still fulfilling requirements like heat conductivity for manufacturing methods utilizing a se lective melting of layers of metal powder and/or metal alloy powder. According to further embodiments the supported prod uct has been manufactured by selectively melting layers of metal powder and/or metal alloy powder, wherein the connec tion is adapted to conduct the heat away from the currently processed layer. This allows to significantly increase the speed of the manufacturing procedures, as the cooling down of each layer before a new powder layer is applied can be short ened. For example, it is possible to realize the required heat conductivity by including a multitude of thin walls or thin pillars preferably direct in the same direction distrib uted over a larger area. For example, such thin walls provide little resistance against breaking in one direction, while they provide a significant increase the stability in two di rections. Thin pillars on the other hand provide little re sistance against such breaking force into the directions, while the structure is stable direction of such pillar. Such multitude of thin walls or thin pillars allow to easily tai lor the breaking behavior based on requirements while still the heat conductivity can be tailored based on the number of walls and pillars provided.

A further method to provide a generic design method especial ly allowing to automate the attachment of support structures to products utilizes different types of connection areas. Ac cording to further embodiments it is preferred that the con nection provides at least one first connection area and at least one second connection area, wherein the connection pro vides a higher stability within the at least one first con nection area compared to the connection within the at least one second connection area. Such higher stability can, for example, be shown by replacing the structure of the connec tion within the first connection area by the structure of the connection utilized in the second connection area for deter mining the stability of the supported product by means of an example or simulation. Also, such determination may be di rectly realized by simulating the stability. Typically, it is preferred that especially the stability perpendicular to the side to be placed upon is determined. For example, such high er stability can be realized by including thicker structures connecting the product and the support structure. An example of a support structure that can be used for such higher sta bility is a wall like structure containing holes. For exam ple, the second area can be filled with a thin walled lattice structure. An example of such structure is known to the skilled person as Magics structure.

According to further embodiments it is preferred that the at least one first connection area and the at least one second connection area each provides an area based on the theoreti cal surface area of the product within the area of the con nection in case the support structure including the connec tion would be removed, wherein the area of each of the at least first connection area provides a size of the at least 1%, more preferred at least 2%, even more preferred at least 2.5%, of the total size of the area of the at least one first connection area and the at least one second connection area. This allows to concentrate on specific design features more simply monitored during the additive manufacturing procedure. Thus, problems or failures during the manufacturing procedure can be more easily spotted and corrected before the supported product is finished.

According to further embodiments it is preferred that the at least one first connection area and the at least one second connection area each provides an area based on the theoreti cal surface area of the product within the area of the con nection in case the support structure including the connec tion would be removed, wherein the area of each of the at least second connection area provides a size of the at least 7%, more preferred at least 9%, even more preferred at least 10%, of the total size of the area of the at least one first connection area and the at least one second connection area. For typical embodiments it was especially beneficial to pro vide such large areas of the second connection areas. It was noted that in case of failures during the manufacturing pro cedure requiring a manual detachment of the product from the support structure through the connection providing such large areas of the second connection allows to more easily and swiftly remove the support structure.

While it is possible to provide complex structures for the connection, it was noted that very simple structures already provides the desired properties simplifying the design and manufacturing procedure. According to further embodiments it is preferred that the total size of the area of the at least one first connection area and the at least one second connec tion area amounts to 100% of the area of the connection.

A very simple and beneficial type of first connection area takes the shape of a line extending through the connection. According to further embodiments it is preferred that the at least one first connection area contains at least one linear first connection area, more preferred each of the at least one first connection area is a linear area. For the sake of completeness, it is pointed out, and that such linear area does not have to be straight, but can also, for example, be curved. Providing such linear first connection areas result ing in wall like structures provide a significant stability along the wall, while the stability is significantly de creased perpendicular to such wall like structure. Further more, it was surprisingly noted that the properties of such wall like structure can be easily tailored as desired.

According to further embodiments it is preferred that the at least one first connection area is a linear area being en closed by the at least one second connection area. For exam ple, it can be realized in form of a central linear firm con nection between the product and the support structure, where in on each side of this first connection area the second con nection area of lower stability is located. For example, the connection can consist of one central linear first connection area enclosed by two second connection areas. Such design is especially useful to be applied to provide an inventive con nection for a multitude of designs.

A further design that can be realized for a multitude of product provides multiple linear areas arranged at opposite sides of the connection. According to further embodiments it is preferred that the at least first connection are two line ar areas located at opposite sides of the connection, wherein the second connection area is located between these two line ar areas. For example, it can be realized in form of two lin ear firm connections limiting the connection on opposite sides, wherein the area between those two linear firm connec tions is provided in form of a second connection area. Howev er, it might also be realized in a comparable form, wherein, for example, a small second connection area is located even behind at least one or both of the first connection areas. In such case these second connection areas represent the outer parts of the connection. In such case, it is typically pre ferred that the distance from the end of the connection to each of the first connection areas is at most 10%, more pre ferred at most 8%, even more preferred at most 4%, of the to tal length of the connection measured perpendicular to the linear first connection.

A further design that can be realized for a variety of dif ferent designs utilizes a first connection area surrounding the second connection area. According to further embodiments it is preferred that the at least one first connection area surrounds a central part of the connection containing a sec ond connection area. Herein, such first connection area can be located at the outer end of the connection or at least one further second connection area can be located adjacent to said first connection area and between the end of the connec tion and said first connection area. In such case, it is typ ically preferred that the distance from the end of the con nection to the first connection areas is at most 10%, more preferred at most 8%, even more preferred at most 4%, of the total length of the connection measured perpendicular to the linear first connection.

For typical designs it was further noted that the ratio of the first connection area and the second connection area is typically above for certain limit. According to further em bodiments it is preferred that the first connection area and the second connection area each provides an area based on the theoretical surface area of the product within the area of the connection in case the support structure including the connection would be removed, wherein the area of the second connection area is at least 3 times, more preferred at least 10 times, even more preferred at least 30 times, the size of the area of the first connection.

A very simple yet efficient structural element that can be utilized for the connection are wall like structures provid ing holes. According to further embodiments it is preferred that the connection provides at least one wall like struc ture, more preferred linear wall like structure, wherein the wall like structure contains holes. It is possible and bene ficial for specific embodiments to provide such wall like structures as circles or in a rectangular shape enclosing an area of the connection. In such cases the connection is typi cally harder to break and provides more freedom for the di rection of the force applied to break off the support struc ture. For typically embodiments, it is, however, preferred to provide a linear wall like structure. In such case a typical ly lower force is necessary and the provision of the specific design is easier and faster. For the sake of completeness, it is pointed out, and that such linear structure does not have to be straight, but can also, for example, be curved. This can be necessary to, for example, adapt to the outer form of the product or to provide a highly defined breaking behavior. Such type of structural element can easily be implemented utilizing automatic design tools as typically used for de signing additive manufacturing instructions.

While testing the manufacturing procedure it was further not ed that the holes included in such wall like structure should beneficially provide a minimum size. According to further em bodiments it is preferred that the connection provides least one wall like structure, more preferred linear wall like structure, wherein the wall like structure contains at least one hole, wherein at least one hole provides connection lines, wherein the connection lines represent lines extending from one side of the hole to the other side of the hole through a center point of the hole, wherein the center point of the hole is a point is a cross section along the center plane of the wall like structure providing the smallest dif ference between the smallest and biggest connection line in the cross section along the center plane of the wall, wherein the smallest connection line of the at least one hole is at least 0.25mm, more preferred 0.3mm. Typically, it is pre ferred that at least 90%, more preferred at least 97%, even more preferred at least 99%, of the holes in the wall like structure provide such diameter, based on the volume of mate rial left out to provide the hole. Typically, it is preferred that all holes provide such minimum size. It was noted that it seems to be far more complicated to achieve comparable re sults utilizing smaller holes.

Surprisingly, it was noted that it is typically beneficial to provide a certain minimum distance between holes especially like those fulfilling the abovementioned minimum size crite ria. According to further embodiments it is preferred that the connection provides at least one wall like structure, more preferred linear wall like structure, wherein the wall like structure contains at least two holes, wherein the holes provide connection lines, wherein the connection lines repre sent lines extending from one side of the hole to the other side of the hole through a center point of the hole, wherein the center point of the hole is a point is a cross section along the center plane of the wall like structure providing the smallest difference between the smallest and biggest con nection line in the cross section along the center plane of the wall, wherein the distance between two neighboring holes, especially two neighboring holes providing the aforementioned minimum size, of at least 90%, more preferred at least 97%, even more preferred at least 99%, of the holes is at least 1.4 times, more preferred at least 1.5 times, even more pre ferred at least 1.7 times, of the smallest connection line of the two neighboring holes, wherein the distance of the two neighboring holes provide is measured from center point to center point, and wherein the percentage of the holes is cal culated based on the volume of material left out to provide the hole.

Furthermore, it was noted that for typical embodiments of the 3D printing it is beneficial to provide a connection provid ing a smoothened transition from the support structure to the product. Parts to be especially beneficially provided in this manner for typical embodiments are wall like structures and first connection areas. According to further embodiments the additive manufacturing is 3D printing providing a printing direction, wherein the connection provides at least one wall like structure, more preferred linear wall like structure, and/or at least one first connection area containing connect ing elements, wherein preferred at least 90%, even more pre ferred at least 95%, even more preferred at least 99%, of the outer surface of the at least one wall like structure and/or the outer surface of the connecting elements provide an angle selected of at least 40°, more preferred at least 42°, even more preferred at least 44°, wherein the angle is measured in relation to a plane perpendicular to the printing direction. Naturally, the smallest angle possible is measured resulting in an upper limit of the angle being measured being 90°. This seems to provide, for example, very stable connections allow ing to significantly divert the forces originating from the weight of the product during the manufacturing process.

Additionally or alternatively such wall like structures can be provided with an indentation, preferably located at the center area of the wall like structure, to further decrease the stability of said structure in one dimension. According to further embodiments it is preferred that the connection provides at least one wall like structure, more preferred linear wall like structure, wherein the wall like structure provides an indentation of the wall like structure in a cross-section perpendicular to the wall like structure over length of at least 90%, more preferred at least 93%, even more preferred at least 96%, of the wall like structure, wherein the term perpendicular to the wall like structure re fers to an orientation being perpendicular to the center plane through the wall like structure. Typically, it is pre ferred that such indentation take the shape of a line like indentation on at least on side of the wall like structure. Such line like indentation preferably typically extends es sentially parallel to the surface of the component. For many applications it is preferred that such indentation is located in a central area of the wall like structure, wherein the central area of the wall like structure represents 60%, more preferred 50%, even more preferred 30%, of the wall like structure extending halfway from the middle of the wall like structure to the component and halfway from the middle of the wall like structure to the support structure.

Such indentation of the wall like structure can, for example, be realized as decreasing thickness of the wall like struc ture. Herein, the thickness of the wall like structure, for example, starting from the support structure first stays con stant. Hereafter, it starts to decrease before reaching a minimum and starting to increase again. Either it increases until it reaches the product or it reaches a defined thick ness before and stays at this thickness value until it reach es the component. While such arrangements are typically bene ficially to be utilized for many applications of the present invention different arrangements to realize such indentation are possible. In general the indentation can, for example, provide a smooth transition equaling a curved surface or a sharp bend when directly switching from decreasing to in creasing thickness.

Such indentations as specified above can be utilized to flex ibly tailor a specific breaking behavior. Surprisingly, it was noted that techniques utilized to lumber can be benefi cially applied to define a breaking direction and prevent, for example, material to be chipped off the product. Typical ly, it is preferred to provide such indentations on both sides of the wall like structure, more preferred linear wall like structure. This allows to easily break the wall like structure from both sides, wherein the crack extends from one indention on one side to the other indentation on the other side. For example, the wall like structure can be shaped like an X in such cross-section to provide a point of minimized stability extending along the wall like structure.

Additionally, it was noted that it is beneficial for typical design tools to define the lower limit of holes to be includ ed in such structural feature. According to further embodi- ments it is preferred that the wall like structure contains at least N holes, wherein

L

N =

2.3 - H

, more preferred L

N =

2.1 - H

,even more preferred

L

N =

1.8 - H

, wherein L is the average length of the wall like structure and H is the average height of the wall like structure. Un less specified otherwise such average value represents the arithmetic mean of said value. For typical embodiments it is preferred that the holes provide an average size in a cross- section along the wall like structure being at least 0.2-H², more preferred at least 0.23-H², even more preferred at least

0.27-H².

Additionally or alternatively it was noted that the simpli fied procedure to provide the inventive connection includes to define an upper limit of the distance of neighboring roles that should be fulfilled. According to further embodiments it is preferred that the wall like structure provides a distance D_n of at most 2-H, more preferred at most 1.6-H, even more preferred at most 1.1-H, between two neighboring holes over at least 90%, more preferred at least 93%, even more pre ferred 96%, of the length of the wall like structure. For typical embodiments it is preferred that the holes provide an average size in a cross-section along the wall like structure being at least 0.2-H², more preferred at least 0.23-H², even more preferred at least 0.27-H².

For example, in case a connection should provide a very inho mogeneous design it was noted that some automated design method containing a specified limit of the distance between the holes is an easy possibility to provide the required re duced stability of such wall like structure. According to further embodiments it is preferred that at least 90%, more preferred at least 94%, even more preferred 98%, of the wall like structure provides a distance D_H of at most 1.4V1.2 S, more preferred at most 1.3V1.2 S , even more preferred at most l.lVl.2 S , wherein S is the average size of each hole in a cross section along the wall like structure, wherein the per centage of the wall like structure is calculated based on the length along the wall like structure, wherein within the cor responding area of the wall like structure two holes are pro vided that fulfill this requirement. For the sake of com pleteness, it is to be understood that said holes do not have to be adjacent holes. For example, a very small hole not ful filling the requirement might be located between two holes fulfilling the requirement still resulting in said area to be included in the calculation of the overall area fulfilling said requirement.

Furthermore, it was noted that the inventive design is espe cially usefully applied to certain materials. Herein, it is preferred for typical embodiments that the supported product consists of metal, a metal alloy, a ceramic material or glass, more preferred of metal or a metal alloy. For example, a group of materials especially suited for this purpose are nickel superalloys.

According to a further aspect the present invention refers to a product manufactured by removing the support structure of the inventive supported product.

Surprisingly, it was noted that the inventive design can be especially beneficially applied to components of a continuous flow engine. Typically, such continuous flow engines utilize a stream of fluid continuously flowing through the engine to rotate a rotor converting the kinetic energy into electrici ty. For example, such fluid stream can be generated by means of burning a fuel using a burner in a gas turbine or boiling a liquid like water in a steam generator. Preferably, the continuous flow engine is a gas turbine. While the inventive design can be utilized for a huge variety of different compo- nents the manufacturing process of components like the hot path components of gas turbine benefit significantly from the inventive design.

According to a further aspect the present invention refers to a method of manufacturing a product containing the steps of

- removing the support structure from the supported product by applying a force in a direction being not perpendicular to the side to be placed upon.

To further simplify the further processing, it was noted that the inventive manufacturing method allows to already include signs or contact points to indicate how force should be ap plied by the operator wanting to removed the support struc ture. According to further embodiments the method contains including a sign and/or contact point on the support struc ture indicating the point or direction to apply force to re move the support structure. This allows to greatly reduce the risk of incorrect application of force for the post pro cessing. Surprisingly, it was noted that the highly flexible manufacturing method brings the risk that the operator trying to remove the support structure might be unsure how to apply the corresponding force. Indicating such information directly on the support structure significantly simplifies the pro cess.

According to a further aspect the present invention refers to a use of the support structure for supporting a product dur ing an additive manufacturing process, wherein the support structure is adapted to be removed to provide the product, wherein the product and the support structure are connected by means of a connection providing different resistances against breaking in different directions. According to a further aspect the present invention refers to a computer program product, tangibly embodied in a machine- readable storage medium, including instructions operable to cause a computing entity to execute an inventive method.

According to a further aspect the present invention refers to a storage device for providing an inventive computer program product, wherein the device stores the computer program prod uct and/or provides the computer program product for further use.

The present invention was only described in further detail for explanatory purposes. However, the invention is not to be understood being limited to these embodiments as they repre sent embodiments providing benefits to solve specific prob lems or fulfilling specific needs. Herein, the specific em bodiments disclosed above can be utilized separately or, preferably, the features of multiple embodiments are com bined. The scope of the protection should be understood to be only limited by the claims attached.

Fig. 1 shows a schematic side view of a guide vane of a gas turbine being an example of the product 2. The left and right side of the guide vane shown in figure 1 provides essentially plain surfaces that can be utilized to start the manufactur ing process utilizing, for example, selective laser melting. However, the middle part as shown requires a support struc ture for building up this part.

Fig. 2 shows a schematic side view of the guide vane of fig ure 1 being supported by multiple inventive support struc tures 3. Herein, the support structure 3 is attached to the product 2 by means of a connection being part of the support structure 3, wherein the connection provides different re sistances against breaking in different directions. In more detail, the connection provides a significant stability against breaking in vertical direction. Simultaneously, the support structure 3 can be easily broken off by applying force using, for example, a hammer on the side of the support structure 3. Herein, the force required to break off the sup port structure 3 applied horizontally is less than 10 of the force required to break it off when applied vertically. The bottom part of the support structure 3 utilized provides a side of the supported product 1 allowing it to be placed on a plane surface.

The connection is designed to conduct the heat away from the currently multiplayer during the additive manufacturing meth od utilizing a metal alloy powder being melted layer by layer to build up the supported product 1. Simultaneously, it pro vides the stability required the complex three-dimensional shape of the product 2.

Fig. 3 shows a schematic side view of figure 2, wherein the arrows 4 indicate the direction the support structure 3 pro vides an increased stability. This direction represents the vertical direction providing the improved stability of the connection as well as the buildup direction during the addi tive manufacturing process.

Not shown in figure 3 is a sign indicating the direction to apply force to break off the support on the side of the sup port structure 3.

Fig. 4 shows a cutout of the schematic side view of figure 2, wherein a part of the connection of the inventive support structure 3 is shown. Herein, the main element 5 of the con nection is shown in part providing the major part of the sta bility in horizontal direction. Said element 5 of the connec tion is located in a linear area extending along the middle part of the guide vane. As shown in figure 4 the element 5 provides a plurality of holes 6 decreasing the strength of said element 5 against a force applied horizontally. Not shown is the weaker connection besides this main element 5 contributing little resistance against breaking of the con nection in horizontal direction. Fig. 5 shows a cutout of a schematic cross-section through a part of the connection connecting the product 2 and the sup port structure. Herein, the main element 5 of the connection providing the main stability in horizontal direction is shown in detail.

Said element 5 provides a linear wall like structure includ ing holes 6 arranged next to each other along the wall like structure. The holes 6 extend over length of more than 98% of the length of the wall like structure.

Furthermore, the wall like structure provides an X-shaped ap pearance with indentations 7 on both sides as can be seen in the cross-section perpendicular to the wall like structure as shown in figure 5. This shape is maintained over the complete length of this element 5.

Not shown in figure 5 are the second connection areas located on both sides of the wall like structure providing vertical support, but little resistance against breaking in horizontal direction.

Fig. 6 shows a cutout of a schematic cross-section showing the part of the connection as shown in figure 5 including the corresponding part of the product 2 and the support structure 3. Figure 6 also does not show the part of the connection be sides the elements 5 explicitly shown in figure 5. The space currently shown empty on the left and right side of said ele ment 5 is filled with a lattice structure being Magics struc ture providing little resistance against force applied hori zontally to break off the support structure 3.

Fig. 7 shows a schematic side view of a clamp being an exam ple of the product 2 as utilized in a gas turbine. The clamp is supported by an inventive support structure 3' represent ing the supported product 1 . Herein, the connection is com parable to the part of the connection as shown in figure 5. However, the connection in this case consists of element 5. The clamp has been manufactured using selective laser melting starting from the bottom of the support structure 3' repre senting the side to be placed upon 8'.

The connection is shown in figure 7 provides the significant ly lower resistance against breaking when applying force di rected parallel to a plane along the side to be placed upon. Although, the force required is already significantly lower such direction, it is even lower the direction slightly in clined to such direction. A corresponding sign indicating this direction available on the side of the support structure 3' is not shown in this figure.

The embodiment is shown in figure 7 only provides this linear wall like structure connecting the support structure 3' around the product. The specific example as shown in figure 7 provides three groups of holes 6' arranged over the length of the connection to further reduce the resistance against breaking when applying force in horizontal direction. Alter natively, the same or different number of holes 6' can also be arranged equidistant over the length of the wall like structure of the connection.

Surprisingly, it was noted that a removal of the remains of the wall like structure is not necessary, although, it can be very easily removed by some grinding step. However, for typi cal applications remains in this case even have been noted to be beneficial. Surprisingly, it was noted that the very small and defined remains of the connection allow to more easily take the clamp by hand and attach it in its predetermined po sition. Especially, when using gloves inserting such parts has been significantly simplified this way.

Fig. 8 shows a cutout of the schematic side view of the sup ported product 1' as shown in figure 7, wherein the end part of the connection supporting the clamp is shown in more de tail. This figure clearly shows the indentations 1 on both sides of the wall like structure of the connection. The in dentations 1 extend over the complete length of the wall like structure. Furthermore, figure 8 more clearly shows the five holes 6' available at the end of the wall like structure. Identical groups of holes 6' are located in the middle and the opposite end of the wall like structure, as can be seen in figure 7. The present invention was only described in further detail for explanatory purposes. However, the invention is not to be understood being limited to these embodiments as they repre sent embodiments providing additional benefits to solve spe cific problems or fulfilling specific needs. The scope of the protection should be understood to be only limited by the claims attached.

Claims

Patent claims

1. Supported product (1, 1") manufactured using additive manufacturing, preferably 3D printing, wherein the supported product (1, 1") contains a product (2, 2") and a support structure, wherein the product (2, 2") and the support structure (3, 3") are connected by means of a connection providing different resistances against breaking in different directions.

2. Supported product (1, 1") according to claim 1, wherein the connection provides at least one linear wall like struc ture, wherein the wall like structure contains holes (6, 6"), wherein the wall like structure providing indentation (7, 7") of the wall like structure in a cross-section perpendicular to the wall like structure over length of at least 90% of the linear wall like structure.

3. Supported product (1, 1") according to any of claims 1 to 2, wherein the connection provides at least one linear wall like structure, wherein the wall like structure contains holes (6, 6'), wherein the wall like structure contains at least X holes (6, 6'), wherein

, wherein L is the average length of the wall like structure and H is the average height of the wall like structure.

4. Supported product (1, 1") according to any of claims 1 to 3, , wherein the connection provides at least one linear wall like structure, wherein the wall like structure contains holes (6, 6'), wherein at least 90% of the wall like structure provides a distance DH of at most 1.4 Vl.2 S , wherein S is the average size of each hole (6, 6") in a cross section along the wall like structure, wherein the percentage of the wall like structure is calculated based on the length along the wall like structure, wherein within the corresponding area of the wall like structure two holes (6, 6") are provided that ful fill this requirement.

5. Supported product (1, 1") according to any of claims 1 to 4, wherein the connection provides at least one first con nection area and at least one second connection area, wherein the connection provides a higher stability within the at least one first connection area compared to the connection within the at least one second connection area

6. Supported product (1, 1") according to claim 5, wherein the first connection area and the second connection area each provides an area based on the theoretical surface area of the product within the area of the connection in case the support structure including the connection would be removed, wherein the area of the second connection area is at least 3 times the size of the area of the first connection.

7. Supported product (1, 1") according to any of claims 1 to 6, wherein the supported product (1, 1") provides a side to be placed upon, wherein the connection provides a higher resistance against breaking perpendicular to the side to be placed upon than parallel to a plane along the side to be placed upon, wherein the force required for breaking of the support struc ture (3, 3") perpendicular to the side to be placed upon is at least 3 times the force required for breaking of the sup port structure (3, 3") parallel to a plane along the side to be placed upon.

8. Supported product (1, 1") according to any of claims 1 to 7, wherein the supported product (1, 1") has been manufac tured by selectively melting layers of metal powder and/or metal alloy powder, wherein the connection is adapted to con duct the heat away from the currently processed layer.

9. Supported product (1, 1") according to any of claims 1 to 8, wherein the connection provides at least one first con nection area and at least one second connection area, wherein the connection provides a higher stability within the at least one first connection area compared to the connection within the at least one second connection area, wherein the at least one first connection area is a linear area being en closed by the at least one second connection area.

10. Product (2, 2") manufactured by removing the support structure (3, 3") of the supported product (1, 1") according to any of claims 1 to 9.

11. Method of manufacturing a product (2, 2") containing the steps of

- manufacturing a supported product (1, 1") according to any of claims 1 to 9 using additive manufacturing, preferably 3D printing, wherein the product (2, 2") provides a side (8") to be placed upon, wherein the support structure (3, 3") is lo cated at this side (8") to be placed upon, and

- removing the support structure (3, 3") from the supported product (1, 1") by applying a force in a direction being not perpendicular to this side (8") to be placed upon.

12. Method of manufacturing a product (2, 2") according to claim 10, wherein the method contains including a sign and/or contact point on the support structure (3, 3") indicating the point or direction to apply force to remove the support structure.

13. Use of the support structure (3, 3") for supporting a product (2, 2") during an additive manufacturing process, wherein the support structure (3, 3") is adapted to be re moved to provide the product, wherein the product (2, 2") and the support structure (3, 3") are connected by means of a connection providing different resistances against breaking in different directions.

14. Computer program product, tangibly embodied in a ma chine-readable storage medium, including instructions opera ble to cause a computing entity to execute a method according to any of claims 11 to 12.

15. Storage device for providing a computer program product according to claim 14, wherein the device stores the computer program product and/or provides the computer program product for further use.