IP Library › Granted Patent US 12,296,539
Granted Patent B2
US 12,296,539 · App. 15/725,136 · Granted May 13, 2025

Apparatus and methods for removable support structures in additive manufacturing

Inventors: Muhammad Faizan Zafar (Long Beach, CA); Broc William TenHouten (Rancho Palos Verdes, CA); Antonio Bernerd Martinez (El Segundo, CA); Keith Allen Fleming (Torrance, CA); John Russell Bucknell (El Segundo, CA)
Assignee: DIVERGENT TECHNOLOGIES, INC.
B29C64/40B22F3/02B22F3/1017B22F3/164B22F3/18B22F10/28B22F10/43B22F10/47B22F10/60B22F10/66B23K26/142B23K26/342B23K26/702B29C64/386B33Y10/00B33Y30/00B33Y50/02B22F10/30B22F12/55B22F12/60B22F2202/01B22F2202/06B22F2998/10B22F2999/00
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Quick Facts
Patent No.
US 12,296,539
App. No.
15/725,136
Granted
May 13, 2025
Kind
B2
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.

Claims (11)

1. A support structure for supporting a surface of a build piece of a powder-bed fusion system, the support structure comprising:

a first leg having a length, the first leg attached to the surface at a connection point interface, wherein a first portion of the length is proximate the connection point interface,

a second portion of the length is further from the connection point interface than the first portion of the length; and

an orifice formed in the second portion of the first leg and configured to provide a fluid entry therein such that the fluid applies a force to the first portion of the length of the first leg in order to detach the first portion from the surface.

2. The support structure of claim 1 , wherein a wall thickness of the first portion of the length is less than a wall thickness of the second portion of the length, such that the first portion is configured to break in response to the applied force.

3. The support structure of claim 1 , further comprising:

a second leg, wherein the second leg is attached to the surface at a second connection point interface.

4. The support structure of claim 3 , wherein the orifice is formed from the first leg and the second leg.

5. The support structure apparatus of claim 1 , wherein the force is created by a phase change of the fluid.

6. The support structure of claim 5 , wherein the phase change is from a liquid to a solid.

7. The support structure of claim 6 , wherein the fluid is water.

Assignments (6)
SECURITY INTEREST Recorded Sep 3, 2025
From: ROCHEFORT MANAGEMENT LLC
To: ACQUIOM AGENCY SERVICES LLC
Reel/Frame 073006/0590 →
SECURITY INTEREST Recorded Jan 30, 2025
From: DIVERGENT TECHNOLOGIES, INC.; CZV, INC.
To: ROCHEFORT MANAGEMENT LLC
Reel/Frame 070074/0290 →
RELEASE OF SECURITY INTEREST Recorded Jan 29, 2025
From: WESTERN ALLIANCE BANK
To: DIVERGENT TECHNOLOGIES, INC.
Reel/Frame 070048/0543 →
SECURITY INTEREST Recorded May 30, 2024
From: DIVERGENT TECHNOLOGIES, INC.
To: WESTERN ALLIANCE BANK
Reel/Frame 067569/0171 →
SECURITY INTEREST Recorded Dec 19, 2022
From: DIVERGENT TECHNOLOGIES, INC.
To: WESTERN ALLIANCE BANK
Reel/Frame 062152/0613 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 4, 2017
From: ZAFAR, MUHAMMAD FAIZAN; TENHOUTEN, BROC WILLIAM; MARTINEZ, ANTONIO BERNERD; FLEMING, KEITH ALLEN; BUCKNELL, JOHN RUSSELL
To: DIVERGENT TECHNOLOGIES, INC.
Reel/Frame 043784/0236 →
Continuity (2)
Continuation In Part 15582409 · Apr 28, 2017
Related Publication 20180311733A1 · Nov 1, 2018
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