Support structures for additively-manufactured components and methods of securing a component to a build platform during additive manufacturing

Additively manufactured components include a support structure and a component body integrally formed with the support structure using an additive-manufacturing process. The support structure includes an array of support members and at least some of the support members have a conduction gate such that the array of support members includes conduction gates distributed at a multitude of locations along the vertical axis of the respective support members. Methods of securing a body of a component to a build platform during additive manufacturing include forming a support structure and a component body integrally with the support structure using the additive-manufacturing process, in which the support structure includes an array of support members and at least some of the support members have a conduction gate such that the array of support members includes conduction gates distributed at a multitude of locations along the vertical axis of the respective support members. The support members that include a conduction gate have a first cross-sectional width and the conduction gate has a second cross-sectional width narrower than the first cross-sectional width.

FIELD

The present disclosure pertains to support structures for additively-manufactured components, and methods of securing a component to a build platform during additive manufacturing.

BACKGROUND

When fabricating a component using an additive manufacturing systems such as a powder bed fusion (PBF) system, support structures may be utilized to anchor the component to a build platform and provide a thermally conductive pathway for heat to dissipate from the component. As examples, PBF systems include direct metal laser melting (DMLM) systems, electron beam melting (EBM) systems, selective laser melting (SLM) systems, directed metal laser sintering (DMLS) systems, and selective laser sintering (SLS) systems. These PBF systems involve focusing an energy beam onto a bed of powder to melt or sinter sequential layers of powder to one another to form a component. The powder undergoes rapid changes in temperature, which can create significant residual stresses in the component, the support structure, and/or the build platform. These residual stresses can cause the component and/or the build platform to warp when cooling, or for the component to break away from the support structure, or for the support structure to break away from the build platform, particularly when large temperature gradients exist within the component or the support structure.

Larger support structures may be provided to supply increased holding strength through a larger contact surface between the component and the support structure and/or the support structure and the build platform. However, for large components, larger support structures may conduct a significant amount of heat to the build platform such that the build platform may warp when cooling. In addition, larger support structures tend to require more time and energy to remove relative to smaller support structures during post fabrication processes. On the other hand, smaller support structures have less holding strength and may increase the likelihood of the component breaking away from the support structure and/or the support structure breaking away from the build platform. When the component and/or the build platform warps or breaks away from the support structure, the component may interfere with the recoater of a PBF system, causing a malfunction of the PBF system and/or an unsuccessful build.

Accordingly, there exists a need for improved support structures for additively manufactured components, and for improved methods of supporting a component during additive manufacturing.

BRIEF DESCRIPTION

Aspects and advantages will be set forth in part in the following description, or may be obvious from the description, or may be learned through practicing the presently disclosed subject matter.

In one aspect, the present disclosure embraces additively manufactured components that include a support structure and a component body integrally formed with the support structure using an additive-manufacturing process. The support structure includes an array of support members and at least some of the support members have a conduction gate such that the array of support members includes conduction gates distributed at a multitude of locations along the vertical axis of the respective support members. The support members that include a conduction gate have a first cross-sectional width and the conduction gate has a second cross-sectional width narrower than the first cross-sectional width.

In another aspect, the present disclosure embraces methods of securing a body of a component to a build platform during additive manufacturing. Exemplary methods include forming a support structure and a component body integrally with the support structure using the additive-manufacturing process, in which the support structure includes an array of support members and at least some of the support members have a conduction gate such that the array of support members includes conduction gates distributed at a multitude of locations along the vertical axis of the respective support members. The support members that include a conduction gate have a first cross-sectional width and the conduction gate has a second cross-sectional width narrower than the first cross-sectional width.

These and other features, aspects and advantages will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate exemplary embodiments and, together with the description, serve to explain certain principles of the presently disclosed subject matter.

DETAILED DESCRIPTION

The present disclosure provides support structures for additively-manufactured components, and methods of securing a component to a build platform during additive manufacturing. Exemplary additively-manufactured components include a support structure and a component body integrally formed with the support structure using an additive-manufacturing process. The support structure includes an array of support members, and at least some of the support members have a conduction gate with a narrower cross-sectional width than that of the support member. Although the narrowing of the cross-sectional width of the conduction gates may allow for a support member to more easily fracture at a conduction gate, the conduction gates may slow the rate of heat conduction through the support members to the build platform. The slower rate of heat conduction provided by the conduction gates may increase the likelihood of a successful build, for example, by reducing the accumulation of heat in the build platform and/or by reducing the tendency for a component body and/or the build platform to warp when cooling. Although some support members may break at the conduction gates, the conduction gates may reduce the tendency for large portions of the component body to break away from the support structure and/or for large portions of the support structure to break away from the build platform.

The conduction gates may also provide for a more uniform rate of heat transfer from the support structure to the build platform across various regions of the support structure, which may reduce residual stresses in the support structure and/or in the body of the component. Such reduced residual stresses may correspond to a lower tendency for the support structure to break, for example, at fracture planes where the component body attaches to the support structure and/or where the support structure attaches to the build platform. In some embodiments, the conduction gates may provide an alternate fracture plane. This alternate fracture plane may require less force to break a particular support member of a support structure relative to a support member that does not have a conduction gate. However, the conduction gates may be distributed along the vertical axis of the respective support members so as to separate these alternate fracture planes relative to adjacent support members, which may reduce the tendency for fracture planes to propagate across the support structure in the event that a particular support member fractures. In some embodiments, the conduction gates may provide an alternate fracture plane that selectively allows individual support members to fracture locally where residual stresses are greatest while the vertical separation of the conduction gates may prevent the fracture from propagating, thereby alleviating residual stresses while isolating the location of the fracture to the area where residual stresses are greatest.

It is understood that terms “upstream” and “downstream” refer to the relative direction with respect to fluid flow in a fluid pathway. For example, “upstream” refers to the direction from which the fluid flows, and “downstream” refers to the direction to which the fluid flows. It is also understood that terms such as “top”, “bottom”, “outward”, “inward”, and the like are words of convenience and are not to be construed as limiting terms. As used herein, the terms “first”, “second”, and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “a” and “an” do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.

FIG. 1shows an exemplary additive manufacturing system100. The exemplary additive manufacturing system may include a powder bed fusion (PBF) system, such as a direct metal laser melting (DMLM) system, an electron beam melting (EBM) system, a selective laser melting (SLM) system, a directed metal laser sintering (DMLS) system, or a selective laser sintering (SLS) system. The additive manufacturing system100builds components in a layer-by-layer manner by melting or fusing sequential layers of a powder material to one another. An exemplary additive manufacturing system100includes a powder supply chamber102that contains a supply of powder104, and a build chamber106within which a component108may be additively manufactured in a layer-by-layer manner. The powder supply chamber102includes a powder piston110which elevates a powder floor112during operation of the system100. As the powder floor112elevates, a portion of the powder104is forced out of the powder supply chamber102. A recoater114such as a roller or a blade pushes some of the powder104across a work surface116and onto a build platform118. The recoater114sequentially distributes thin layers of powder104onto the build platform118. An energy source120directs an energy beam122such as a laser or an electron beam onto the thin layer of powder104to melt or fuse the sequential layers of powder104. Typically with a DMLM, EBM, or SLM system, the powder104is fully melted, with respective layers being melted or re-melted with respective passes of the energy beam122. Conversely, with DMLS, or SLS systems, layers of powder104are sintered, fusing particles of powder104with one another generally without reaching the melting point of the powder104.

A scanner124controls the path of the beam so as to melt or fuse only the portions of the layer of powder104that are to become part of the component108. The first layer or series of layers of powder104are typically melted or fused to the build platform118, and then sequential layers of powder104are melted or fused to one another to additively manufacture the component108. The first several layers of powder104that become melted or fused to the build platform118define a support structure126for the component108. As sequential layers of powder104are melted or fused to one another, a build piston128gradually lowers the build platform118so as to make room for the recoater114to distribute sequential layers of powder104. Sequential layers of powder104may be melted or fused to the component108until a completed component108has been fabricated.

Generally the support structure126provides a surface to which sequential layers of powder104may be melted or fused, while holding the sequential layers of melted or fused powder in position while resisting residual stresses caused by rapid changes in temperature as the energy beam122melts or fuses the sequential layers of powder104. The support structure126also provides a thermally conductive pathway to dissipate heat generated by the energy beam122. Typically a support structure126may be fabricated in the same manner as the component108. In some embodiments, the same powder104may be used to fabricate the support structure126and the component108. Alternatively, in some embodiments a different powder104may be used for the support structure126and the component108. When forming the support structure126, typically the energy beam122melts or sinters the top surface of the build platform118together with the first few layers of powder104so as to securely weld (e.g., melt or fuse) the support structure126to the build platform118. After the component108has been fabricated, the support structure126may be removed from the component108in post-fabrication processes. For example, the component108may be cut away from the support structure126using an electrical discharge machine (EDM) such as a wire-cut EDM or other suitable cutting tool.

FIG. 2Ashows an exemplary component108with a support structure126securing the component108to a build platform118.FIG. 2Bshows a cross-sectional view of the support structure126shown inFIG. 2A. The component108may be oriented with reference to a Cartesian coordinate system having an X-axis, a Y-axis, and a Z-axis in which the X-axis and Y-axis define a plane that is generally parallel with the build platform118, and a Z-axis defines an elevation or height of the component108relative to the build platform118. As shown, the component108includes a component body200and the support structure126includes an array of support members202, with both the component body200and the array of support members202having been formed by melting or sintering powder104in a PBF process such as DMLM, EBM, SLM, DMLS, or SLS. The array of support members202may be melted or fused to the build platform118so as to provide a secure connection between the array of support members202and the build platform118. The component body200may be melted or fused to the array of support members202so as to provide a secure connection between the component body200and the array of support members202. As shown, the array of support members202may include a plurality of channels204intermittently spaced throughout the support structure126. The channels204provide a pathway for cleaning out unused powder104during post-fabrication processes. Additionally, the channels204may interrupt or isolate residual stresses in the support structure126caused by rapid changes in temperature during the additive manufacturing process. As shown, the support members202may be oriented with a vertical axis of the support members202being generally parallel with the Z-axis; however, in some embodiments the support members202may be oriented such that the vertical axis has a nonparallel angle relative to the Z-axis. For example, the support members202may have an angle that is equal to or less than 90 degrees, with 90-degrees corresponding to the Z-axis and zero degrees corresponding to the X-axis and/or the Y-axis. The support members202may be oriented at an angle from 0 to 90 degrees, such as from 5 to 85 degrees, such as from 15 to 70 degrees, such as from 30 to 55 degrees, such as from 40 to 50 degrees, such as from 25 to 35 degrees, such as from 55 to 65 degrees.

FIGS. 3A-3Hshow cross-sectional views of exemplary support structures126that include an array of support members202.FIGS. 3A and 3Bshow cross-sectional views along the Y-axis.FIGS. 3C-3Hshow cross-sectional views along the radial-axis, or R-axis. Alternatively,FIGS. 3C-3Hmay be regarded as showing cross-sectional views along the X-axis. Exemplary support structures126may include combinations of the views shown inFIGS. 3A-3H. For example, a support structure126may include the Y-axis view shown inFIG. 3Acombined with any one of the R-axis or X-axis views shown inFIGS. 3C-3H. As another example, a support structure126may include the Y-axis view shown inFIG. 3Bcombined with any one of the R-axis or X-axis views shown inFIGS. 3C-3H. Additionally, it will be appreciated that the respective Y-axis and R-axis or X-axis views may be interchanged with one another, and the particular axis shown inFIGS. 3A-3Hare not to be limiting.

As shown inFIGS. 3A and 3B, the support members202may have narrow cross-sectional profile when viewed along the Y-axis. As shown inFIGS. 3C, 3E, and 3F, the support members202may have an elongate cross-sectional profile when viewed along the R-axis or X-axis. The narrow cross-sectional profile ofFIG. 3A or 3Bmay combine with the elongate cross-sectional profile ofFIG. 3C, 3E, or3F to provide support members that have a rail-like configuration. In some embodiments, a support structure126may include an array of rail-like support members202. By way of example, the rail-like support members may be arranged in annular rows, linear rows, and/or non-linear rows.

As shown inFIGS. 3D, 3G, and 3H, the support members may have a narrow cross-sectional profile when viewed along the R-axis or X-axis, and such narrow cross-sectional profile may combine with the narrow Y-axis cross-sectional profile ofFIG. 3A or 3Bto provide support members that have a post-like configuration. In some embodiments, a support structure126may include an array of post-like support members202. By way of example, the post-like support members may be arranged in annular rows, linear rows, and/or non-linear rows. In still further embodiments, a support structure126may include a combination of rail-like support members and post-like support members.

Still referring toFIGS. 3A-3H, the array of support members202may include a plurality of conduction gates300. At least some of the support members202may include a conduction gate300. A conduction gate300represents a portion of a support member202that has a narrower cross-sectional width than surrounding areas of the support member202. In some embodiments, a support structure126that includes an array of conduction gate300—containing support members202may provide a more uniform rate of heat transfer across the bulk of the support structure126by slowing the rate of conduction through the support members202. The rate of conduction through a support member202may be slowed by a conduction gate300because the narrower cross-sectional area of the conduction gate300reduces the unit area available for conduction, and the reduced area may provide resistance to thermal conduction through the support member202. As the conduction gates300present a resistance to thermal conduction, the rate of conduction through the support structure126may be locally tempered so as to provide a more uniform rate of heat transfer across the bulk of the support structure126.

Additionally, or in the alternative, in some embodiments the conduction gates300may define a fracture plane in a support member202, whereby a support member202may preferentially fracture at a conduction gate300rather than at an interface between the support structure126and the build platform118or between the support structure126and the component body200. When support members202of a support structure126fracture, there can be a tendency for the fracture to follow a fracture plane that may propagate across adjacent support members202, allowing residual forces to warp or curl the body200of the component108and/or the build platform118where the support members202have fractured. The fracture plane may follow a crystalline lattice line, which may correspond to an interface between adjacent layers of melted or fused powder104located within the conduction gate300. Common fracture planes exist at the interface between adjacent layers of melted or fused powder104located where the support structure126attaches to the build platform118and/or where the component body200attaches to the support structure126. However, in some embodiments the conduction gates300may provide an alternate fracture plane, such that the support members202may preferentially fracture at the conduction gate300rather than at an interface between the support structure126and the build platform118or between the support structure126and the component body200. Additionally, a conduction gate300may be located at intermediate position along the vertical axis of a support member202, which location may disassociate the preferential fracture plane of the conduction gate300from the interface where the support structure126attaches to the build platform118and/or where the component body200attaches to the support structure126.

In some embodiments, as shown for example inFIGS. 3A and 3B, a support structure126may include conduction gates300respectively located at a variety of different vertical positions of the corresponding support members202. The vertical position of the conduction gates300may be ascertained, for example, with reference to a Z-axis or vertical axis of the component108. For example, a first support member302may include a first conduction gate304located at a first vertical positon along the vertical axis of the first support member302, and a second support member306may include a second conduction gate308located at a second vertical position along the vertical axis of the second support member306such that the first vertical position of the first conduction gate304differs from the second vertical position of the second conduction gate308. In some embodiments, for example, as shown inFIG. 3A, the first vertical position of the first conduction gate304may be below the second vertical position of the second conduction gate308. The different vertical positions of conduction gates300may separate respective fracture planes, which may reduce the tendency for a fracture to propagate across adjacent support members202. The conduction gates300may allow individual support members to fracture locally where residual stresses are greatest while the vertical disassociation or separation of the conduction gates300may prevent the fracture from propagating, thereby alleviating residual stresses while isolating the location of the fracture to the area where residual stresses are greatest. It will be appreciated that while exemplary embodiments show the support members202having a vertical axis oriented along the Z-axis, in some embodiments the support members202may be angled relative with respect to the Z-axis, in which case the vertical axis may refer to the corresponding axis along the length of the support members from the build platform118to the component body200.

In some embodiments, an array of support members202may be segmented according to a plurality of intervals206(FIG. 2B) distributed across the support structure126, such as along a radial axis, the X-axis and/or the Y-axis. The intervals206may further interrupt or isolate residual stresses in the support structure126caused by rapid changes in temperature during the additive manufacturing process. As shown inFIG. 2B, an array of support members may include a first interval208, a second interval210, a third interval212, a fourth interval214, a fifth interval216, a sixth interval218, and so on. It will be appreciated that the six intervals shown inFIG. 2Bare provided by way of example only and are not intended to be limiting. Rather, any number of intervals may be provided in accordance with the spirit and scope of the present disclosure. For example, referring again toFIG. 3A, the conduction gates300may be distributed at a multitude of locations along the vertical axis of the respective support members that make up an interval206of the support structure126. In some embodiments, the conduction gates300may be distributed along the vertical axis of the respective support members202in a step-wise manner309across an interval206(e.g., the second interval210), for example, as shown inFIG. 3A. Such step-wise distribution of conduction gates300may be linear or nonlinear.FIG. 3Bshows another example of conduction gates300distributed along an interval206in a step-wise manner. With conduction gates300distributed along the vertical axis of respective support members202, a series of fracture planes associated with the conduction gates may be provided which traverses multiple layers of melted or sintered powder104. This arrangement may further reduce the tendency for a fracture to propagate across adjacent support members202.

As shown inFIG. 3B, in some embodiments a support structure may include intervals206that overlap. For example, a first interval208may overlap a second interval210, and a second interval210may overlap a third interval212. In some embodiments, conduction gates300may be distributed at a multitude of locations along the vertical axis of the respective support members202corresponding to a respective overlapping interval206. The overlapping intervals206, together with the distribution of the conduction gates300across the vertical axis of the respective support members202, may combine to provide a sequence of conduction gates300, for example, that alternate between high and low positions along the vertical axis of the respective support members202. In one embodiment, a first interval208and a second interval210may overlap one another, with each interval respectively including conduction gates300distributed along the respective interval206in a step-wise manner. The vertical position of the conduction gates300may alternate in sequence between the respective overlapping intervals206. The overlapping intervals206(e.g., a first interval208and a second interval210) are shown by way of example only and not to be limiting. It will be appreciated that any number of overlapping intervals may be provided within the spirit and scope of the present disclosure. The series of fracture planes corresponding to the overlapping alternating locations of the conduction gates may further reduce the tendency for a fracture to propagate across adjacent support members202.

In some embodiments, as shown inFIG. 3B, an array of support members202within overlapping intervals206(e.g., a first interval208or a second interval210) may include a first support member302associated with a first interval208, a second support member306associated with a second interval210, and a third support member310associated with the first interval208. The first support member302may include a first conduction gate304located at a first position along the vertical axis of the first support member302, the second support member306may include a second conduction gate308located at a second vertical position along the vertical axis of the second support member306, and the third support member310may include a third conduction gate312located at a third vertical position along the vertical axis of the third support member310. The first vertical position of the first conduction gate204may be above the second vertical position of the second conduction gate308, and the third vertical position of the third conduction gate312may be above the second vertical position of the second conduction gate308, for example, as ascertained with reference to the Z-axis of the component108. In some embodiments, the third vertical position of the third conduction gate312may be below the first vertical position of the first conduction gate204. The conduction gates300associated with the first interval208may be distributed along the vertical axis of the respective support members202in a first step-wise manner309, and the conduction gates300associated with the second interval210may be distributed along the vertical axis of the respective support members202in a second step-wise manner313.

As shown inFIG. 3C, a conduction gate300may extend across an elongate support member202. As shown inFIG. 3D, an array of support members202may have conduction gates that align with one another at a given location along the vertical axis of the support members202in respect of one axis (e.g., the Y-axis). In some embodiments, such aligned conduction gates shown inFIG. 3Dmay vary along the vertical axis of the support member in respect of another axis (e.g., the R-axis or the X-axis), such as shown inFIGS. 3A and 3B. As shown inFIGS. 3E and 3F, a conduction gate300may extend across an elongate support member202with a slope, which slope may be linear (FIG. 3E), step-wise (FIG. 3F), or non-linear (not shown). As shown, for example, inFIG. 3Gin combination withFIG. 3Aand/or inFIG. 3Hin combination withFIG. 3B, a support structure126may include an array of support members202with conduction gates300distributed along the vertical axis of the respective support members202in a manner that varies in respect of both the Y-axis and the R-axis or X-axis. In some embodiments, a variation in the location of the conduction gates300along the vertical axis of the respective support members202may vary in a manner that is consistent as between the Y-axis and the R-axis, or as between the Y-axis and the X-axis.

The distribution of the conduction gates300along the vertical axis of the respective support members202and/or across an interval206of the support structure118may follow any desired pattern, including an ordered pattern, a random pattern, or a semi-random pattern. As shown inFIGS. 3A and 3G, the location of the center point of the conduction gates300may be distributed across an interval206at a vertical position according to the following equation: z(n)=(s×n)−s/2, where z is the vertical position of the conduction gate between 0 and L, n is the support member number in the interval206, and s is the length of the conduction gate300, and where the equation continues up to L and then repeats, where L is the length of the support member202. As shown inFIGS. 3B and 3H, the conduction gates300are distributed across a first interval208and a second interval210at a vertical position according to the following respective equations: z(n1)=(s×n1)−s/2+0.5 L; and z(n2)=(s×n2)−s/2; where z is the vertical position of the conduction gate300between 0 and L, n1is the support member number in the first interval208, n2is the support member number in the second interval210, and s is the length of the conduction gate300, and where the equations continue up to L and then repeat, where L is the length of the support member202.

The location of the conduction gates300may be distributed along the vertical axis of the respective support members202within an array of support members202of a support structure126in both the X and Y directions. For example,FIGS. 4A-4Cshow a grid400representing exemplary spatial locations of conductions gates300on the support members202within an interval206of a support structure126. The grid400may include at least a portion of the first interval208, the second interval210, and/or the third interval212, and so on, of the support structure126. Each box402in the grid400represents a conduction gate300. The X and Y position of the box402in the grid400reflect the relative X and Y position of the corresponding conduction gate300within the interval206of the support structure126. The numerical value404in the box402corresponds to the location of the corresponding conduction gate300along the Z-axis or vertical axis of the support member202. As shown inFIG. 4A, the location of the conduction gates300along the vertical axis of the support members may vary across the X-axis while remaining constant across the Y-axis, or vice versa. As shown inFIG. 4B, the location of the conduction gates300along the vertical axis of the support members202may vary across both the X and Y axis of the support structure126. As shown inFIG. 4B, the intervals206may overlap in both the X and Y direction of the support structure126.

Any number of support members202may be included in an interval206of a support structure126. For example, as shown inFIGS. 3A, 3B, 3G, and 3H, an interval206may include ten (10) support members202. The number of support members202shown are provided by way of example only and not to be limiting. In some embodiments, an interval206may include from 1 to 50 support members202, such as from 5 to 25 support members202, such as from 5 to 15 support members202, such as from 8 to 12 support members202, such as from 25 to 50 support members202, or such as from 35 to 40 support members202. An interval206may include at least 5 support members202, such as at least 10 support members202, such as at least 15 support members202, such as at least 20 support members202, such as at least 25 support members202, such as at least 35 support members202, such as at least 45 support members202. An interval206may include 50 support members202or less, such as 40 support members202or less, such as 30 support members202or less, such as 20 support members202or less, such as 15 support members202or less, or such as 10 support members202or less.

A support structure126may include support members202that have any desired width and length, or any desired combination of widths and lengths. In some embodiments, a support structure126may include support members202that are from 1 to 100 mm long, such as from 1 to 10 mm, such as from 1 to 5 mm, such as from 2 to 5 mm, such as from 3 to 6 mm, such as from 5 to 20 mm, such as from 10 to 20 mm, such as from 15 to 20 mm, such as from 20 to 100 mm, such as from 25 to 50 mm, such as from 50 to 75 mm, or such as from 75 to 100 mm. The support members200may be at least 1 mm long, such as at least 2 mm, such as at least 3 mm, such as at least 5 mm, such as at least 10 mm, such as at least 15 mm, such as at least 25 mm, such as at least 50 mm, or such as at least 75 mm. The support members202may be less than 100 mm long, such as less than 75 mm, such as less than 50 mm, such as less than 25 mm, such as less than 20 mm, such as less than 15 mm, such as less than 10 mm, such as less than 5 mm, such as less than 3 mm, or such as less than 2 mm.

In some embodiments, a support structure126may include support members202that are from 500 to 10,000 micrometers wide, such as from 750 to 7,500 μm, such as from 1,000 to 5,000 μm, such as from 750 to 2500 μm, such as from 1,000 to 2,500 μm, such as from 1,000 to 2,000 μm, such as from 1,250 to 1,750 μm, such as from 1,400 to 1,600 μm, such as from 1,500 to 3,000 μm, such as from 1,500 to 2,500 μm, or such as from 2,000 to 2,750 μm. A support structure may include support members200that are at least 500 micrometers wide, such as at least 750 μm, such as at least 1,000 μm, such as at least 1,250 μm, such as at least 1,500 μm, such as at least 1,750 μm, such as at least 2,000 μm, such as at least 2,250 μm, such as at least 2,500 μm, such as at least 2,750 μm, such as at least 5,000 μm, or such as at least 7,500 μm. A support structure may include support members200that are less than 10,000 micrometers wide, such as 7,500 μm or less, such as 5,000 μm or less, such as 3,000 μm or less, such as 2,750 μm or less, such as 2,500 μm or less, such as 2,250 μm or less, such as 2,000 μm or less, such as 1,750 μm or less, such as 1,500 μm or less, such as 1,250 μm or less, such as 1,000 μm or less, or such as 750 μm or less.

A support structure126may include support members202with a conduction gate300that has any desired width and length, or support members202that include a conduction gate300that has any desired combination of widths and lengths. In some embodiments, a support member202may have a conduction gate300ranging from 10 to 6,000 micrometers long, such as from 50 to 5,000 μm, such as from 100 to 2,500 μm, such as from 50 to 1,200 μm, such as from 100 to 1,000 μm, such as from 200 to 800 μm, such as from 400 to 600 μm, such as from 150 to 500 μm, such as from 150 to 300 μm, such as from 500 to 700 μm, such as from 700 to 1,100 μm, or such as from 800 to 1,000 μm. A conduction gate300may be at least 10 micrometers long, such as at least 50 μm, such as at least 100 μm, such as at least 250 μm, such as at least 500 μm, such as at least 750 μm, such as at least 1,000 μm, such as at least 2,500 μm, or such as at least 5,000 μm. A conduction gate300may be less than 5,000 μm long, such as less 4,000 μm or less, such as 2,500 μm or less, such as 1,200 μm or less, such as 1,000 μm or less, such as 750 μm or less, such as 500 μm or less, such as 250 μm or less, or such as 100 μm or less.

In some embodiments, a support member202may have a conduction gate300ranging from 10 to 3,000 micrometers wide, such as from 50 to 5,000 μm, such as from 100 to 2,500 μm, such as from 50 to 1,200 μm, such as from 100 to 1,000 μm, such as from 200 to 800 μm, such as from 400 to 600 μm, such as from 150 to 500 μm, such as from 150 to 300 μm, such as from 500 to 700 μm, such as from 700 to 1,100 μm, or such as from 800 to 1,000 μm. A conduction gate300may be at least 10 micrometers wide, such as at least 50 μm, such as at least 100 such as at least 250 μm, such as at least 500 μm, such as at least 750 μm, such as at least 1,000 μm, such as at least 2,500 μm, or such as at least 5,000 μm. A conduction gate300may be less than 5,000 μm long, such as less 4,000 μm or less, such as 2,500 μm or less, such as 1,200 μm or less, such as 1,000 μm or less, such as 750 μm or less, such as 500 μm or less, such as 250 μm or less, or such as 100 μm or less.

In some embodiments, the support members202may have a cross-sectional profile corresponding to any polyhedral shape, including circular, semi-circular, oval, rectangular, polyhedral, or combinations of these.FIGS. 5A-5Cshow exemplary side-profiles of support members202that have conduction gates300with various side profiles. As shown inFIG. 5A, a conduction gate300may have a rectangular side profile. As shown inFIG. 5B, a conduction gate300may have a frustoconical side profile. As shown inFIG. 5C, a conduction gate300may have an hourglass side profile. The side profiles shown inFIGS. 5A-5Care provided by way of example and are not to be limiting. It will be appreciated that a support structure126may include support members202that have conduction gates300with any desired side profile, all of which are within the sprit and scope of the present disclosure.

FIGS. 5D-5Hshow exemplary cross-sections of support members202that have conduction gates300. As shown inFIG. 5D, a support member202may have an elongate cross-section, such as corresponding to a rail-like configuration. As shown inFIGS. 5E-5H, a support member202may have a narrow-cross-section, such as corresponding to a post-like configuration. As shown inFIG. 5E, a support member202may have a rectangular cross-section, and the support member202may have a conduction gate300with a rectangular cross-section. As shown inFIG. 5F, a support member202may have a circular cross-section, and the support member202may have a conduction gate300with a circular cross-section. As shown inFIG. 5G, a support member202may have a rectangular cross-section, and the support member202may have a conduction gate300with a circular cross-section. As shown inFIG. 5H, a support member202may have a circular cross-section, and the support member202may have a conduction gate300with a rectangular cross-section. The cross-sections shown inFIGS. 5D-5Hare provided by way of example and are not to be limiting. It will be appreciated that a support structure126may include support members202with any desired cross-section as well as conduction gates300with any desired cross-section, all of which are within the sprit and scope of the present disclosure.

Various components108and their respective support structures126may be formed according to the present disclosure using any desired materials compatible with a PBF system. Exemplary materials include metals and metal alloys, such as metals or metal alloys that include tungsten, aluminum, chromium, copper, cobalt, molybdenum, tantalum, titanium, nickel, steel, and combinations thereof, as well as superalloys, such as austenitic nickel-chromium-based superalloys. Further exemplary materials include plastics, ceramics and composite materials.

Now turning toFIG. 6, exemplary methods of securing a component to a build platform during additive manufacturing will be discussed. Exemplary methods may be performed using an additive-manufacturing system100including those described herein. An exemplary method600includes forming a support structure using an additive-manufacturing process602and forming a component body integrally with the support structure using the additive-manufacturing process604. The support structure126may include an array of support members202and at least some of the support members202may include a conduction gate300such that the conduction gates300are distributed at a multitude of locations along the vertical axis of the respective support members202. The support members202that include a conduction gate300may have a first cross-sectional width and the conduction gate300may have a second cross-sectional width narrower than the first cross-sectional width. In some embodiments, the additive-manufacturing process may include powder bed fusion (PBF).

As examples, the additive-manufacturing process may include direct metal laser melting (DMLM), electron beam melting (EBM), selective laser melting (SLM), directed metal laser sintering (DMLS), and/or selective laser sintering (SLS). The support structure and/or the component body may be formed using a powder104, such as a powder104that includes a metal or metal alloy, a plastic, a ceramic, and/or a composite. As examples, a metal or metal alloy powder may include tungsten, aluminum, chromium, copper, cobalt, molybdenum, tantalum, titanium, nickel, and steel, and combinations thereof, as well as superalloys, such as austenitic nickel-chromium-based superalloys.