Method and apparatus for optimisation of the supports for the additive manufacturing of a component with a recess

1. A method for obtaining, by additive manufacturing, a one-piece blank component including at least one recess ( 27 ), including:

a step of forming the one-piece blank component by additive manufacturing on a build plate (T), during which:

at least one recess comprises an upper inner portion ( 57 ) that needs to be supported, and a lower inner portion ( 58 ) opposite the upper inner portion ( 57 ), and

a support ( 60 ) is formed in said at least one recess, the support including a core ( 61 ) provided with a hole ( 66 ) and cellular elements (S 1 ; S 2 ) including at least one lower module (S 1 ) that connects the lower inner portion ( 58 ) to the core ( 61 ), and an upper module (S 2 ) that connects the core ( 61 ) to the upper inner portion ( 57 );

a step of detaching the support ( 60 ) from the blank component in order to expose the recess ( 27 ), comprising:

an engagement of an insertion end ( 69 ) of a tool ( 67 ) in the hole ( 66 ), then

a rotation of the core ( 61 ) by the tool ( 67 ) inducing a rupture of the lower and upper modules (S 1 , S 2 ) for the extraction of the core ( 61 ).

2. The method according to claim 1 , wherein the step of detaching the support ( 60 ) includes a finishing step to suppress residues from lower and upper modules (S 1 , S 2 ) remained attached to the recess ( 27 ).

3. The method according to claim 1 , wherein:

the lower module (S 1 ) is erected from all or at least one portion of the lower inner portion ( 58 ), while forming a bearing surface for the formation of the core from a lower surface of core ( 64 ) opposite all or at least one portion of this lower inner portion ( 58 ), and

the upper module (S 2 ) is erected from all or at least one portion of an upper surface of core ( 63 ) opposite the upper inner portion ( 57 ), while forming a bearing surface for the formation of this upper inner portion ( 57 ).

4. The method according to claim 1 , wherein the core ( 61 ) has free form surfaces, while comprising at least one portion opposite the lower inner portion ( 58 ) that does not require being supported during the manufacture of the core ( 61 ).

5. The method according to claim 4 , wherein:

the recess is a duct comprising a cylindrical portion ( 53 ) and a bulging portion ( 54 ) that extends the cylindrical portion ( 53 ); with

the upper inner portion ( 57 ) forming a cylinder portion along the cylindrical portion ( 53 ) and the bulging portion ( 54 );

the lower inner portion ( 58 ) forming a cylinder portion along the cylindrical portion ( 53 ) and following a contour as an arched groove ( 56 ) in the bulging portion ( 54 );

the core including a portion of constant section in the cylindrical portion ( 53 ) and a bevelled portion that extends the portion of constant section in the bulging portion ( 54 ) by forming a ramp ( 62 ) facing the lower inner portion ( 58 ) following a contour as an arched groove, this ramp not needing to be supported during the additive manufacturing.

6. The method according to claim 5 , wherein the portion of constant section of the core ( 61 ) located in the cylindrical portion ( 53 ) is oblong.

7. The method according to claim 5 , wherein the transition between the ramp ( 62 ) and the portion of constant section of the core is marked by the interface between the cylindrical portion ( 53 ) and the bulging portion ( 54 ) of the recess.

8. The method according to claim 1 , wherein the hole ( 66 ) includes a square section of which the sides are oriented at 45° with respect to the build plate (T).

9. The method according to claim 1 , wherein the component is a bearing support ( 21 ).

10. An aircraft engine comprising a bearing support ( 21 ) manufactured with the method according to claim 9 .