Vibration-induced self-severing support members

Abstract

A three-dimensional (3D) printed object includes a first surface and a second surface spaced apart from the first surface. A support member is integrally formed with the first surface at a first point coincident with the first surface and is integrally formed with the second surface at a second point, distal from the first point and coincident with the second surface. A first pair of masses is integrally formed along a length of the support member, at least one of the first pair of masses configured to vibrate with a first predetermined mode of vibration in response to a first vibration of the 3D printed object at a first predetermined frequency. The support member is configured to self-sever from the 3D printed object at or adjacent to the first point in response to the first vibration at the first predetermined frequency. The vibration induces fatigue substantially at the first point.

Description

VIBRATION-INDUCED SELF-SEVERING SUPPORT MEMBERSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application for patent claims priority to and the benefit of provisional patent application number 63 / 615,587 entitled “Vibration-Induced Self-Severing Support Members” filed in the United States Patent and Trademark Office on December 28, 2023, the entire content of which is incorporated herein by reference as if fully set forth below in its entirety and for all applicable purposes.TECHNICAL FIELD

[0002] Aspects described herein are generally related to manufacturing three- dimensional (3D) printed objects and are more particularly related to 3D printed objects incorporating one or more vibration-induced self-severing support members.BACKGROUND

[0003] A three-dimensional-printed (a 3D printed) object (e.g., a structure, a part, a component, a unit) may be realized as a plurality of slices. Many 3D printed objects may be manufactured using an additive process. In the additive process, the 3D printed object is manufactured on a platen (also referred to as a build plate or a base) in a powder bed of an apparatus that applies (e.g., spreads) a layer of powder (e.g., a fusible, meltable powder), smooths the surface of the layer of powder, fuses portions of the layer of powder in a shape assigned to that layer while concurrently fusing that shape to the previously formed layers below the present layer, lowers the powder bed, and repeats the process. The apparatus may repeat these steps hundreds, thousands, or tens of thousands of times depending at least on the size of the 3D printed object and the resolution of the apparatus executing the task of 3D printing. In this way, the 3D printed object is built up layer-by-layer, slice-by-slice. Eventually, the 3D printed object is completed. Because each successive layer is fused with the preceding layer, the completed 3D printed object may be formed as an integral unit. In some examples, 3D printed objects may be manufactured with metal powder. However, 3D printed objects may be manufactured using other powdered materials such as, for example, and without limitation, composite materials, carbon fiber, or plastic.

[0004] Because the 3D printer lowers the platen and applies a new layer of powder atop each preceding layer, after the 3D printing process is complete, the 3D printed object is buried in unfused powder within the powder bed. The unfused powder fills the spaces around and between the solid spaces formed of fused powder. The solid spaces formed of fused powder take on the form of the 3D printed object. At the start of or before a post-manufacturing process, the 3D printed object is removed from the powder bed, and the unfused powder is removed (e.g., by vacuum) from the spaces around and between the solid spaces.

[0005] After the unfused powder is removed, some features (e.g., structural features) of the 3D printed object may, for example, and without limitation, overhang, bridge, or be cantilevered above the spaces previously occupied with unfused powder. Because the unfused powder was removed from such previously occupied spaces, such previously occupied spaces may be referred to as void spaces herein. Even though occupied with unfused powder during the printing process, the unfused powder may not offer sufficient support to the overhanging, bridged, or cantilevered portions of the 3D printed object during the printing process. Without support during the printing process, these overhanging, bridged, or cantilevered features of the 3D printed object may be acted upon by the force of gravity as they are built up (during the printing process). These features may droop, sag, bend, or otherwise be deflected, deformed, or displaced into what will become the void spaces under their own weight and any weight that they, in turn, may directly or indirectly support. To avoid having unsupported or inadequately supported features of the 3D printed object droop, sag, bend, or otherwise deflect, deform, or be displaced, support features may be fabricated (as the 3D printed object is built up during the printing process) as integral features of the 3D printed object. Such integral support features may be referred to as support members herein. The support members may serve as supporting and / or bracing structures to the features that overhang, bridge, cantilever, etc., the ultimately void spaces.

[0006] The support members may preserve the structural integrity and intended shape, orientation, position, and / or location in 3D space of the features they support as layers are built atop such features (e.g., where such features overhang, bridge, cantilever, etc., the ultimately void spaces). However, the support members are temporary. As a part of the post-processing of the 3D printed object, the support members, which are not required for structural integrity or to preserve any specific shape or the overallshape of the final 3D printed object, are severed from the 3D printed object. The severed support members may, subsequent to their severance, be removed from the void spaces around and between the solid final pieces of the 3D printed object. Depending at least in part on their quantity, location, or both, the work of severing and removing the support members may be, for example, tedious, detailed / delicate, labor- intensive work that may be done by hand.

[0007] Scientists and engineers continue to search, for example, for more efficient, less time-consuming, less burdensome, and minimally destructive ways to sever support members from the body of 3D printed objects during, for example, post-manufacture processing.BRIEF SUMMARY

[0008] The following summary is provided to facilitate an understanding of some of the innovative features unique to the examples disclosed and is not intended to be a full description. A full appreciation of the various aspects of the examples can be gained by taking the entire specification, claims, drawings, and abstract as a whole.

[0009] In one example, a three-dimensional (3D) printed object is described. The 3D printed object includes a first surface of the 3D printed object and a second surface of the 3D printed object, spaced apart from the first surface. The 3D printed object includes a support member between the first surface and the second surface. The support member is integrally formed with the first surface at a first point coincident with the first surface and is integrally formed with the second surface at a second point, distal from the first point and coincident with the second surface. The 3D printed object also includes a first pair of masses integrally formed along a length of the support member, at least one of the first pair of masses configured to vibrate with a first predeterm ined mode of vibration in response to a first vibration of the 3D printed object at a first predetermined frequency. According to some aspects, the support member is configured to self-sever from the 3D printed object at or adjacent to the first point in response to the first vibration at the first predetermined frequency, which induces fatigue in the support member at or adjacent to the first point.

[0010] In another example, a method of manufacturing a three-dimensional (3D) printed object is described. The method of manufacturing the 3D printed object includes printing, in a 3D printer, a first surface of the 3D printed object and printing, in the 3Dprinter, a second surface of the 3D printed object, spaced apart from the first surface. The method of manufacturing the 3D printed object also includes printing, in the 3D printer, a support member between the first surface and the second surface is integrally formed with the first surface at a first point coincident with the first surface and integrally formed with the second surface at a second point, distal from the first point and coincident with the second surface. The method of manufacturing the 3D printed object also includes printing, in the 3D printer, a first pair of masses integrally formed along a length of the support member, at least one of the first pair of masses configured to vibrate with a first predetermined mode of vibration in response to a first vibration of the 3D printed object at a first predetermined frequency. Once the 3D printed object is completed in the 3D printer, the method of manufacturing the 3D printed object includes removing the 3D printed object from the 3D printer and vibrating, after the removing, the 3D printed object at the first predetermined frequency. According to the method, the support member is configured to self-sever from the 3D printed object at or adjacent to the first point in response to the vibrating at the first predetermined frequency.

[0011] These and other aspects will become more fully understood upon a review of the detailed description which follows. Other aspects, features, and examples will become apparent to those of ordinary skill in the art upon reviewing the following description of specific exemplary aspects in conjunction with the accompanying figures. While features may be discussed relative to certain examples and figures below, all examples can include one or more of the advantageous features discussed herein. In other words, while one or more examples may be discussed as having certain advantageous features, one or more of such features may also be used in accordance with the various examples discussed herein. Similarly, while examples may be discussed below as device, system, or method examples, it should be understood that such examples can be implemented in various devices, systems, and methods.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The accompanying figures, in which like reference numerals refer to identical or functionally similar elements throughout the separate views and which are incorporated in and form an object of the specification, further illustrate the examplesand, together with the detailed description, serve to explain the aspects disclosed herein.

[0013] FIG. 1 illustrates three configurations of 3D printed objects used herein for exemplary and non-limiting purposes according to some aspects of the disclosure.

[0014] FIG. 2 is a front elevation cross-sectional orthogonal projection of a 3D printed object according to some aspects of the disclosure.

[0015] FIG. 3 is a front elevation cross-sectional orthogonal projection of a 3D printed object according to some aspects of the disclosure.

[0016] FIG. 4 is an enlarged view of a portion of FIG. 3 with a further enlarged inset view according to some aspects of the disclosure.

[0017] FIG. 5 is the front elevation cross-sectional orthogonal projection of the 3D printed object according to some aspects of the disclosure.

[0018] FIG. 6 is a perspective view of one example of a 3D printed object that includes a support member that is configured as a wall or web with an integral first mass and an integral second mass according to some aspects of the disclosure.

[0019] FIG. 7 is a flow chart illustrating an example process of manufacturing a 3D printed object according to some aspects of the disclosure.DETAILED DESCRIPTION

[0020] The particular values and configurations discussed in the following non-limiting examples can be varied and are cited merely to illustrate one or more examples and are not intended to limit the scope thereof.

[0021] Examples will now be described more fully hereinafter with reference to the accompanying drawings. The examples disclosed herein can be modified within the scope of this disclosure and should not be construed as limiting; instead, these examples are provided so that this disclosure will be thorough and complete and fully convey the scope of the disclosure to persons of ordinary skill in the art. Like numbers refer to like elements throughout.

[0022] The detailed description set forth below in connection with the appended drawings is intended as a description of various configurations and is not intended to represent the only configurations in which the concepts described herein may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of various concepts. However, it will be apparentto persons having ordinary skill in the art that these concepts may be practiced without these specific details. In some examples, well-known structures and components are shown in block diagram form in order to avoid obscuring such concepts.

[0023] The terminology used herein is for the purpose of describing particular examples only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise” and / or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0024] Throughout the specification and claims, terms may have nuanced meanings suggested or implied in context beyond an explicitly stated meaning. Likewise, the phrase “in one example,” as used herein, does not necessarily refer to the same example, and the phrase “in another example” does not necessarily refer to a different example. It is intended that the scope of disclosure may encompass the subject matter of one or more examples in whole or in part.

[0025] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by a person having ordinary skill in the art. It will be further understood that terms, such as those defined in dictionaries, should be interpreted as having their ordinary meaning and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0026] It will be understood that particular examples described herein are shown by way of illustration and not as limitations. Aspects described herein can be employed in various examples without departing from the scope of the disclosure. Those persons having ordinary skill in the art will recognize or be able to ascertain, using no more than routine experimentation, numerous equivalents to the specific aspects and procedures described herein. Such equivalents are considered to be within the scope of this disclosure and are covered by the claims.

[0027] The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and / or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” The use of the term “or” in the claims is used to mean “and / or” (e.g., A and / or Bcontemplates A and B, or A, or B) unless explicitly indicated to refer to alternatives only, or the alternatives are mutually exclusive. However, the disclosure supports a definition that refers to only alternatives and “and / or.” Throughout this application, the term “about” is used to indicate that a value includes an inherent variation of error for a device or the method being employed to determine the value, that a value is reasonably close to, or that a value may include a reasonable variation or range.

[0028] As used in this specification and claim(s), the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

[0029] The term “or combinations thereof” as used herein refers to all permutations and combinations of the listed items preceding the term. For example, “A, B, C, or combinations thereof” is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, expressly included are combinations that contain repeats of one or more items or terms, such as BB, AAA, AB, BBC, AAABCCCC, CBBAAA, CABABB, and so forth. The person having ordinary skill in the art will understand that there is no limit on the number of items or terms in any combination unless otherwise apparent from the context.

[0030] All of the aspects disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the aspects have been described in terms of preferred examples, it will be apparent to persons having ordinary skill in the art that variations may be applied to the aspects described herein without departing from the concept, spirit, and scope of the disclosure and claims. All such substitutes and modifications apparent to those persons having ordinary skill in the art are deemed to be within the spirit, scope, and concept of the disclosure as defined by the appended claims.

[0031] Methods of removing the support members may be dependent on the type of material used to fabricate the 3D printed object. For example, in association with a 3D printed object fabricated using plastic, a chemical may be used to remove a support member. However, while a chemical may dissolve a plastic support member exposedto the chemical (which is desired), the chemical may also dissolve all other exposed surfaces of the 3D printed object (which is not desired). Additionally, chemicals may not be suitable for many applications. For example, chemicals may be ineffective in 3D printed objects fabricated of metal.

[0032] Other examples of methods used to remove a support member include manually removing the support member with mechanical hand tools such as cutters (e.g., diagonal cutters, side cutters, flush cutters, semi-flush cutters), scalpels, needle nose pliers, files, probes, and / or tweezers (all being non-limiting examples of the term “tool”) that may be used to cut, twist, break, or otherwise manipulate one or both ends of the support member to a point of a fatigue fracture (e.g., to the point of breaking and separating). Other examples of methods used to separate a support member include the use of rotary and / or oscillating / vibrating miniature tools (e.g., circular saw blades or cut-off wheels driven by a Dremel® tool), miniature oscillating saws or devices, and / or other tools driven with electrical power or compressed / pressurized air (all being additional non-limiting examples of the term “tool”), which may be used to sever an end of a support member from the body of the 3D printed object. Such manual and powered removal work is tedious, time-consuming, at times delicate, and labor- intensive. The removal work is also challenging in locations of the completed 3D printed object with limited access. In addition, a need to perform the removal work may prohibit specific designs due to an inability to access spaces that include one or both ends of a support member (e.g., a space into which it would be impossible or challenging to insert a tool). Furthermore, inserting tools into the interior spaces of the 3D printed object and removing the support members from those interior spaces risks damaging the completed 3D printed object.

[0033] In addition to chemical methods and mechanical methods utilizing manual or powered tools, some support members (e.g., a support member having any cross- sectional shape observed in a plane perpendicular to a longitudinal axis of the support member, where the cross-sectional shape is constant along an entire length of the support member, such as a right circular cylinder with a constant cross-sectional area along its entire length) have been removed using a shaking method. The shaking method may be performed during post-processing. According to the shaking method, the completed 3D printed object is shaken (e.g., vibrated) at the 3D printed object’snatural frequency. The natural frequency corresponds to the frequency at which a system tends to oscillate in the absence of any driving force.

[0034] The motion pattern of a system oscillating at its natural frequency is called the normal mode (if all parts of the system move sinusoidally with that same frequency). Shaking the 3D printed object at its natural frequency may separate some support members from the 3D printed object. However, the mechanism of removal is essentially the ripping apart of the support members due to the stretching caused by the surfaces of the 3D printed object moving at the natural frequency. This shaking method is unreliable because support members may either break at places other than where the desired break should occur (e.g., break in half with both ends of the support member still attached to the body of the 3D printed object) or not break at all. Moreover, the shaking of the 3D printed object at its natural frequency is likely to damage the 3D printed object.

[0035] Described herein are support members that may be configured to respond at a frequency other than the 3D printed object’s natural frequency. This other frequency, different from the natural frequency of the 3D printed object, may be referred to herein as a “support member resonant frequency.” Vibrating the 3D printed object at the support member resonant frequency may be safe for the 3D printed object because the support member can be configured to self-sever from the body of the 3D printed object at a support member resonant frequency that is different from the natural frequency of the 3D printed object. Additionally, according to some examples, all support members can be configured to self-sever from a first surface of the 3D printed object at a first support member resonant frequency and then self-sever from a second surface of the 3D printed object (where support members occupy a space between the first and second surfaces) at a second support member resonant frequency. The second support member resonant frequency may also be offset from (different from) the natural frequency of the 3D printed object.

[0036] Still further, according to some examples, a support member may be configured to fragment (e.g., first break at one or more locations along its length) in response to being vibrated at one or more predetermined support member resonant frequencies. Then, the support member may be further configured to self-sever at its opposing ends (a first end and a second end) from the two surfaces to which it is integrally coupled to the body of the 3D printed object by application of the first support member resonantfrequency and the second support member resonant frequency, respectively. Facilitating the fracture of the support member into two or more unattached pieces (where each piece is shorter than the total length of the original support member) may aid in the removal of the fractured pieces of the support member from areas of the 3D printed object that have limited accessibility. For example, it may be easier to eject two or more small fragments of a support member through a given opening than eject the unfractured original length of the support member through the same opening.

[0037] Furthermore, vibrating the 3D printed object at one or more predetermined support member resonant frequencies may provide a more consistent solution to support member removal in comparison to the solution achieved by vibrating the 3D printed object at its natural frequency.

[0038] According to some aspects, self-severing support members may be configured to sever (e.g., fracture and separate at a point coincident with a body of the 3D printed object or at a point along the length of the self-severing support member) at predesignated breakaway points. According to some aspects of the disclosure, a selfsevering support member may be configured to include at least two masses located at predetermined positions along the length of the support member. The predetermined positions along the length of the support member may correspond to predetermined distances from one another and predetermined distances from the support member / 3D printed object breakaway point(s). The masses, their placements relative to one another, and their placements relative to the support member / 3D printed object breakaway points may be used to configure the support member to vibrate / flex at predetermined locations and predetermined support member resonant frequencies and thereby induce fatigue (and fracture) at the predetermined locations. The induced fatigue may result in the self-severing (by vibration at locations determined by placement of integrated masses along the length of the support member) of the support member from the 3D printed object at the predetermined location.

[0039] Support members configured according to aspects described herein may have any cross-sectional shape. For example, some support members may be circular or multi-sided columns. Such support members could be configured to fatigue at support member / 3D printed object breakaway points (where the fatigue is induced by vibration at one or more support member resonant frequencies). Other support members maybe rectilinear (e.g., a planar web, a thin wall) bridging between two surfaces of the 3D printed object. Such support members could be configured to fatigue at support member / 3D printed object breakaway lines (e.g., a linear reference segment (a line) along the length of the rectilinear support member at the margin between the rectilinear support member and body of the 3D printed object) where the fatigue is induced by vibration at the one or more support member resonant frequencies.

[0040] FIG. 1 illustrates three configurations of 3D printed objects used herein for exemplary and non-limiting purposes according to some aspects of the disclosure. An X-Y coordinate system is provided for reference purposes. Here, X extends along a horizontal axis, Y extends along a vertical axis, the origin is at the intersection of the X-axis and Y-axis, and Z (not shown) extends perpendicularly from the X-Y plane (out of the surface of the paper).

[0041] As used herein, the terminology vertical, horizontal, side, front, rear, top, bottom, above, below, left, and right may all reference spatial relationships between points in the X-Y coordinate system or between objects and / or refer to views of objects in the drawings appended hereto; their use is for exemplary and non-limiting purposes. Similarly, the shapes of the objects in the drawing are presented for convenience and not limitation. Several drawings herein present orthographic (2D) views of the 3D printed objects to simplify the drawings.

[0042] A first 3D printed object 100 is depicted in a side elevation view. The first 3D printed object 100 includes a first vertical feature 102 projecting upward from a platen 122 (e.g., a build-plate, a base) and a first angled feature 104 projecting from the top of the first vertical feature at about 30 degrees from the vertical. The first angled feature 104 overhangs a first predetermined space 111 (bounded on its left edge by a dashed (imaginary) line), as shown. The first vertical feature 102 and the first angled feature 104 are integral to one another (formed by fusing successive layers of material) and collectively form the first 3D printed object 100. Aside from its fused integral attachment to the top of the first vertical feature 102, nothing supports the first angled feature 104 in the first predetermined space 111 between the first angled feature 104 and the platen 122 beneath the first angled feature 104.

[0043] A second 3D printed object 103 is depicted in a side elevation view and has a cross-section formed in a chair-like shape. The second 3D printed object 103 includes a first leg feature 108 and a spaced-apart second leg feature 110. The first leg feature108, and the spaced-apart second leg feature 110, projects vertically upward from the platen 122. A horizontal feature 106 bridges atop and between the first leg feature 108 and the spaced-apart second leg feature 110. The first leg feature 108 also supports at least part of a vertical monolithic feature 114. The vertical monolithic feature 114 is slightly wider than the first leg feature 108. The first leg feature 108, the spaced-apart second leg feature 110, the horizontal feature 106, and the vertical monolithic feature 114 are integral to one another (formed by fusing successive layers of material) and collectively form the second 3D printed object 103. Aside from its fused integral attachment at the tops of the first leg feature 108 and the spaced-apart second leg feature 110, nothing supports the horizontal feature 106 in the second predetermined space 112 between first leg feature 108 and the spaced-apart second leg feature 110 and below the horizontal feature 106 above the platen 122.

[0044] A third 3D printed object 105 is depicted in a side elevation view having a crosssection formed in an inverted L-like shape. The third 3D printed object 105 includes a vertical column feature 116 having any cross-section (not shown) and a horizontal arm feature 118 extending at a right angle from the top of the vertical column feature 116. The vertical column feature 116 projects perpendicularly upward from the platen 122. The horizontal arm feature 118 does not have a constant depth along the horizontal axis. It is narrower in a given region 120 between the top of the vertical column feature 116 and the first third of a length along the horizontal arm feature 118. The vertical column feature 116 and the horizontal arm feature 118 are integral to one another (formed by fusing successive layers of material) and collectively form the third 3D printed object 105. Aside from its fused attachment to the top of the vertical column feature 116, nothing supports the horizontal arm feature 118 in the third predetermined space 113 (bounded on its right edge by a dashed (imaginary) line) beneath the horizontal arm feature 118 and above the platen 122.

[0045] FIG. 2 is a front elevation cross-sectional orthogonal projection of a 3D printed object 200 according to some aspects of the disclosure. The 3D printed object 200 includes a body 202. A space (e.g., an interior space, a void space) of the 3D printed object 200 that is not bounded on all sides by some portions of the interior of the body 202 is bounded in the example of FIG. 2 between a first surface 204 (e.g., an upper interior surface), a left interior surface 206, a right interior surface 208, and a second surface 210. The second surface 210 includes a portion of a working surface 210-1 ofa platen 222 (e.g., a build-plate, a base) (e.g., where the 3D printed object 200 is printed on the working surface 210-1 of the platen 222), a center-bottom surface 210-2, and a right-bottom surface 210-3 (individually or in any combination referred to herein as the second surface 210), where the second surface 210 is spaced apart from the first surface 204. A bridge feature 216 is illustrated for purposes of example and not limitation.

[0046] In the example of FIG. 2, support members between the underside of the bridge feature 216 and the working surface 210-1 of the platen 222 are not required. A reason for not requiring support members beneath the bridge feature 216 may be due to the thickness and width of the bridge feature 216. Of course, nothing herein precludes the fabrication of one or more support members beneath the bridge feature 216.

[0047] In contrast to the bridge feature 216, the integral cover feature 218 of the 3D printed object 200 is, for purposes of this example, required to have support members (not shown in FIG. 2). A reason for requiring support members beneath the integral cover feature 218 may be due to the thickness and width of the integral cover feature 218. The thickness (in the Y direction) of the integral cover feature 218 is less than the thickness of the bridge feature 216. The width (in the X direction) of the integral cover feature 218 is greater than the width of the bridge feature 216. Without support members, the integral cover feature 218 may deform (e.g., sag) due to gravity alone or due to additional layers (not shown) including some structure (not shown) positioned atop the integral cover feature 218.

[0048] The interior space of the 3D printed object 200 below the first surface 204 of integral cover feature 218 of the body 202 may be divided into three sub-spaces. A first sub-space 220 may be bounded (at its top and bottom) between the first surface 204 of the body 202 and the working surface 210-1 of the platen 222. The projection of the integral cover feature 218 into the first sub-space 220 falls onto the working surface 210-1 of the platen 222.

[0049] A second sub-space 224 may be bounded (at its top and bottom) between the first surface 204 of the body 202 and the center-bottom surface 210-2 of the 3D printed object 200. The projection of the integral cover feature 218 into the second sub-space 224 falls onto the center-bottom surface 210-2 of the 3D printed object 200.

[0050] A third sub-space 226 may be bounded (at its top and bottom) between the first surface 204 of the body 202 and the right-bottom surface 210-3 of the 3D printed object200. The projection of the integral cover feature 218 into the third sub-space 226 falls onto the right-bottom surface 210-3 of the 3D printed object 200.

[0051] FIG. 3 is a front elevation cross-sectional orthogonal projection of a 3D printed object 300 according to some aspects of the disclosure. In FIG. 3, the 3D printed object 300 is on a platen 322 (e.g., a build-plate, a base).

[0052] Similar to the 3D printed object 200 of FIG. 2, the 3D printed object 300 of FIG. 3 includes a body 302. A space (e.g., an interior space, a void space) of the 3D printed object 300 that is not bounded on all sides is bounded in the example of FIG. 3 between a first surface 304 (e.g., an upper interior surface), a left interior surface 306, a right interior surface 308, and a second surface 310 (i.e., a working surface 310-1 of a platen 322, a center-bottom surface 310-2, a right-bottom surface 310-3, individually or in any combination referred to herein as the second surface 310), where the second surface 310 is spaced apart from the first surface 304. A bridge feature 316, for purposes of this example, does not require one or more support members beneath it. It is noted that while the space (e.g., the interior space, the void space) of the 3D printed object 300 may not be bounded on all sides in the exemplary illustration of FIG.3, boundaries may exist in front of and behind the X-Y plane of the drawing at least in the form of the walls of the printing chamber (not shown) within which the 3D printed object is fabricated. As will be understood by those having ordinary skill in the art, the walls of the printing chamber (not shown) and the platen 322 confine the unfused powder (e.g., metal powder, plastic powder, etc.) to a defined space as successive layers of powder are applied to the 3D printed object and the platen 322 is repeatedly lowered into the printing chamber during the fabrication process.

[0053] In the example of FIG. 3, an integral cover feature 318 of the 3D printed object 300 is, for purposes of this example, required to have support members beneath it. As with FIG. 2, the interior space of the 3D printed object 300 below the first surface 304 of integral cover feature 318 of the body 302 may be divided into three sub-spaces. A first sub-space 320, a second sub-space 324, and a third sub-space 326. The descriptions of the three sub-spaces of FIG. 3 are the same as or similar to the descriptions of the three sub-spaces of FIG. 2. The descriptions will not be repeated to reduce duplication and for the sake of brevity. In contrast to FIG. 2, to avoid cluttering the drawing, cross-hatching within the interior space of the body 302 of FIG. 3 is not used to distinguish between the first sub-space 320, the second sub-space324, and a third sub-space 326; instead, the first sub-space 320, the second subspace 324, and the third sub-space 326 are identified with brackets above the integral cover feature 318.

[0054] The 3D printed object 300 of FIG. 3 includes a first support member 331 , a second support member 332, a third support member 333, a fourth support member 334, a fifth support member 335, a sixth support member 336, and a seventh support member 337. Each of the seven support members is integrally formed with the 3D printed object 300 during the 3D printing process. Although shown as lines in FIG. 3 for ease of illustration, the support members may be configured, for example, as rods or shafts, having circular, elliptical, square, rectangular, polygonal, etc. cross-sections, or configured, for example, as ribbons, webs, walls, or the like, as shown in the example of the third support member 333 as illustrated in FIG. 4. A plurality of support members may be formed with one or more configurations. For example, it is within the scope of this disclosure for the seven support members depicted in FIG. 3 to be configured as any one of, or any combination of, rods, shafts, ribbons, webs, walls, etc., having any one or more cross-sections.

[0055] In FIG. 3, the first support member 331 is depicted as being coupled to the working surface 310-1 of the platen 322. Indeed, the first layer deposited on the working surface 310-1 of the platen 322 included the lowest surface of the first support member 331 . Each succeeding layer of the first support member 331 may be built atop the first layer; each succeeding layer adds to the structure of what is ultimately described as the first support member 331 . When the 3D printed object 300 is removed from the platen 322, the coupling of the first support member 331 to the working surface 310-1 of the platen 322 is severed (as shown in FIG. 5).

[0056] Each of the seven support members, except the second support member 332, includes at least two masses. For ease of reference in this disclosure, each mass of a given support member will be identified by the support member reference number followed by a numeral corresponding to an identifier of a respective mass of the given support member. For example, the first mass of the first support member 331 will be identified with reference number 331 -1 . The second mass of the first support member 331 will be identified with reference number 331 -2.

[0057] Accordingly, the first support member 331 includes a first mass 331 -1 and a second mass 331 -2. The second support member 332 includes a first mass 332-1.The third support member 333 includes a first mass 333-1 , a second mass 333-2, a third mass 333-3, and a fourth mass 333-4. The fourth support member 334 includes a first mass 334-1 , a second mass 334-2, a third mass 334-3, and a fourth mass 334-4. The fifth support member 335 includes a first mass 335-1 , a second mass 335-2, a third mass 335-3, and a fourth mass 335-4. The sixth support member 336 includes a first mass 336-1 , a second mass 336-2, a third mass 336-3, and a fourth mass 336-4. The seventh support member 337 includes a first mass 337-1 , a second mass 337-2, a third mass 337-3, a fourth mass 337-4, a fifth mass 337-5, and a sixth mass 337-6. The numbers, positions, and illustrated arrangements of the various masses on the different support members are for illustrative and non-limiting purposes.

[0058] Each of the first support member 331 , the second support member 332, and the third support member 333 are vertical, oriented perpendicular to the X-Z plane and, in the example of FIG. 3, perpendicular to the planes of the first surface 304 and the planes of both the working surface 310-1 of the platen 322 and the center-bottom surface 310-2 of the body 302 of the 3D printed object 300. However, orientations that are different than perpendicular are within the scope of the present disclosure.

[0059] Any support member may be oriented perpendicularly to, or at an angle to, an adjacent surface (e.g., the first surface 304, the working surface 310-1 , the centerbottom surface 310-2, or the right-bottom surface 310-3) without departing from the scope of the disclosure. It is noted that the breakaway points 341 , 342, 343, 344, 345, 346, 347, 352, 353, 354, 355, 356, and 357 (individually referred to variously as a point, a first point, a second point, a breakaway point, a proximal breakaway point, or a distal breakaway point herein) are integrally formed with their respective adjacent surfaces; a distal breakaway point 351 of the first support member 331 is formed atop (e.g., contiguously) its adjacent (e.g., adjoining) surface, the working surface 310-1.

[0060] Furthermore, although shown as lying in planes perpendicular to the X-Z plane, any surface (e.g., the first surface 304, the working surface 310-1 , the center-bottom surface 310-2, or the right-bottom surface 310-3) of the 3D printed object 300 that is adjacent to a breakaway point of a given support member (whether integrally formed with an adjacent surface or contiguously formed with the adjacent surface (e.g., the distal breakaway point 351 )) may be at any angle relative to the X-Z plane, the X-Y plane, and the Y-Z plane without departing from the scope of the disclosure. Accordingly, the fourth support member 334, and the fifth support member 335, areprovided as non-limiting examples of non-perpendicular (e.g., relative to a plane of a surface that is continuous with the support member) support members.

[0061] The sixth support member 336 provides an example of a support member similar (e.g., in length) to the first support member 331 but anchored to two spaced apart surfaces of the body 302 of the 3D printed object 300 (i.e., namely the first surface 304 at a proximal breakaway point 346 and the right-bottom surface 310-3 at a distal breakaway point 356). The sixth support member 336 also includes, in contrast to the first support member 331 , two masses adjacent to the distal breakaway point 356 (the third mass 336-3 and the fourth mass 336-4).

[0062] The seventh support member 337 provides an example of a support member with three pairs of masses: a first mass 337-1 and a second mass 337-2, a third mass 337-3 and a fourth mass 337-4, and a fifth mass 337-6 and a sixth mass 337-6. The additional pair of masses (in the example of FIG. 3, the third mass 337-3 and the fourth mass 337-4 positioned approximately midway along the length of the seventh support member 337) may be used in connection with a vibratory frequency applied to sever the seventh support member 337 into two pieces, prior to applying one or more other vibratory frequencies to sever the two pieces from the body 302 at the proximal breakaway point 347 and a distal breakaway point 357.

[0063] Six of the seven support members are continuously formed at their opposing ends with an adjacent (e.g., intersecting, terminating) surface of the body 302 of the 3D printed object 300. Consequently, six of the seven support members are formed continuously with (e.g., formed integrally with) the entire body 302 of the 3D printed object 300. The first support member 331 (e.g., the first of the seven support members) is integrally formed at the end adjacent to a proximal breakaway point 341 with a surface of the body 302 of the 3D printed object 300. However, at the opposing end, the first support member 331 is contiguously coupled to the working surface 310-1 .

[0064] Although the illustrated support members have a right circular cylinder shape (depicted as lines in FIG. 3), the use of a right circular cylinder shape is for ease of illustration and not limitation. Any shapes or combinations of shapes of columnar support members (e.g., support members with cross sections that are, for example, and without limitation, circular, oval, square, rectangular, equal-sided-polygonal, non- equal-sided-polygonal) are within the scope of the disclosure. Additionally, as shown in FIG. 6, a support member may be, for example, a wall having a rectangular cross-section (e.g., in both the X-Y and X-Z planes). Other shapes and cross-sections and other combinations of shapes and cross-sections of support members are within the scope of the disclosure.

[0065] For ease of reference herein, and without any intent of limiting the scope of the disclosure by the words chosen, a first end of a support member adjacent to the integral cover feature 318 may be referred to herein as a proximal end, and a second end of the support member adjacent to the working surface 310-1 of the platen 322, or the center-bottom surface 310-2, or the right-bottom surface 310-3, may be referred to herein as a distal end. Additionally, the three dimensional location immediately surrounding the conjunction of a given support member and an adjacent (e.g., intersecting, terminating, anchoring) surface of the body 302 of the 3D printed object 300 will be referred to herein as a breakaway point (e.g., in connection with descriptions of the examples of FIGs. 3, 4, and 5) or a breakaway line (e.g., in connection with the description of the example of FIG. 6).

[0066] For example, the proximal breakaway point 341 of the first support member 331 may be observed at the conjunction of the first support member 331 and the first surface 304. A distal breakaway point 351 of the first support member 331 may be observed at the conjunction of the first support member 331 and the working surface 310-1 of the platen 322.

[0067] A proximal breakaway point 342 of the second support member 332 may be observed at the conjunction of the second support member 332 and the first surface 304. A distal breakaway point 352 of the second support member 332 may be observed at the conjunction of the second support member 332 and the center-bottom surface 310-2 of the body 302 of the 3D printed object 300.

[0068] A proximal breakaway point 343 of the third support member 333 may be observed at the conjunction of the third support member 333 and the first surface 304. A distal breakaway point 353 of the third support member 333 may be observed at the conjunction of the third support member 333 and the center-bottom surface 310-2 of the body 302 of the 3D printed object 300.

[0069] A proximal breakaway point 344 of the fourth support member 334 may be observed at the conjunction of the fourth support member 334 and the first surface 304. A distal breakaway point 354 of the fourth support member 334 may be observedat the conjunction of the fourth support member 334 and the right-bottom surface 310-3 of the body 302 of the 3D printed object.

[0070] A proximal breakaway point 345 of the fifth support member 335 may be observed at the conjunction of the fifth support member 335 and the first surface 304. A distal breakaway point 355 of the fifth support member 335 may be observed at the conjunction of the fifth support member 335 and the right-bottom surface 310-3 of the body 302 of the 3D printed object.

[0071] A proximal breakaway point 346 of the sixth support member 336 may be observed at the conjunction of the sixth support member 336 and the first surface 304. A distal breakaway point 356 of the sixth support member 336 may be observed at the conjunction of the sixth support member 336 and the right-bottom surface 310-3 of the body 302 of the 3D printed object.

[0072] A proximal breakaway point 347 of the seventh support member 337 may be observed at the conjunction of the seventh support member 337 and the first surface 304. A distal breakaway point 357 of the seventh support member 337 may be observed at the conjunction of the seventh support member 337 and the right-bottom surface 310-3 of the body 302 of the 3D printed object.

[0073] In addition, an intermediate point 307 (e.g., an intermediate breakaway point), may be observed between the third mass 337-3 and the fourth mass 337-4 of the seventh support member 337. In other examples, the intermediate point 307 may be above the third mass 337-3 or below the fourth mass 337-4 without departing from the scope of the disclosure.

[0074] The intermediate point 307 may be used to flex, fatigue, and then break (sever) the support member along its length (at its center in this example for illustrative and non-limiting reasons) by inciting a first predetermined mode of vibration in the seventh support member 337. Then, a second predetermined mode of vibration may induce the upper half of the seventh support member 337 to sever from the upper interior surface at the proximal breakaway point 347. Next, a third predetermined mode of vibration may induce the lower half of the seventh support member 337 to sever from the right-bottom surface 310-3 at the distal breakaway point 357. The first predetermined mode of vibration may be different from the second and third predetermined modes of vibration. The second and third modes of vibration may be the same or different. In some examples, the first, second, and third predeterminedmodes of vibration may be the same. The intermediate point 307 may be located anywhere between the proximal breakaway point 347 and the distal breakaway point 357 of the seventh support member 337 without departing from the scope of the disclosure.

[0075] Using the seventh support member 337 as a visual reference and for exemplary and non-limiting purposes, according to some aspects, the 3D printed object 300 may include a first surface 304 of the 3D printed object 300, a second surface 310 of the 3D printed object 300, spaced apart from the first surface 304. For ease of explanation, a space 408 of FIG. 4 (e.g., a void) is bounded at least between the first surface 304 and the second surface 310 (e.g., 310-2 of FIG. 4) is identified in the illustration of FIG. 4. The 3D printed object 300 may further include a seventh support member 337 between the first surface 304 and the second surface 310 and integrally formed with the first surface 304 at a first point 347 (i.e., the proximal breakaway point 347) coincident with the first surface 304 and with the second surface 310 at a second point 357 (i.e., the distal breakaway point 357), distal from the first point 347 and coincident with the second surface 310.

[0076] In other words, the 3D printed object 300 may further include a seventh support member 337, integrally formed with the first surface 304 at the first point 347 (e.g., a proximal breakaway point) coincident with the first surface 304 and the seventh support member 337 and integrally formed with the second surface 310 at a second point 357 (i.e., the distal breakaway point 357), distal from the first point 347 and coincident with the second surface 310.

[0077] The 3D printed object 300 may still further include a first pair of masses (e.g., a first mass 337-1 and a second mass 337-2) integrally formed along a length (e.g., a vertical length, which in this example of the seventh support member 337 lies parallel to the Y-axis) of the seventh support member 337, at least one of the first pair of masses (e.g., the first mass 337-1 ) configured to vibrate with a first predetermined mode of vibration in response to a first vibration of the 3D printed object 300 at a first predetermined frequency, where the seventh support member 337 is configured to self-sever from the 3D printed object 300 at or adjacent to the first point 347 (i.e., the proximal breakaway point 347) in response to the first vibration at the first predetermined frequency, which induces fatigue (e.g., metal fatigue) in the seventh support member 337 at or adjacent to the first point 347.

[0078] According to some aspects, when the 3D printed object 300 is fabricated in metal (e.g., using a metal powder fused in a 3D printer), the fatigue may be referred to as a structural fatigue, a metal fatigue, or a fatigue fracture. In a metal fracture, for example, progressive structural damage occurs in the metal when subjected to repeated cycles of loading and unloading or bending back and forth in response to the first vibration at the first predetermined frequency applied to the 3D printed object. According to some aspects, metal fatigue may result in a fracture at stress levels lower than the yield strength of the metal.

[0079] According to some aspects, the first predetermined frequency is different from a natural frequency of the 3D printed object 300.

[0080] According to some aspects, (with reference to the seventh support member 337) the at least one of the first pair of masses is a first mass (e.g., the first mass 337-1 ) and another one of the first pair of masses is a second mass (e.g., the second mass 337-2), and the first predetermined mode of vibration is configured to vibrate the first mass 337-1 with a first amplitude and to vibrate the second mass 337-2 with a second amplitude, less than the first amplitude. In some examples, the second amplitude may be zero (i.e. , no vibration). In some examples, the second amplitude is at least two to twenty times less or, more specifically, four to fifteen times less, or even more specifically, six to ten times less than the first amplitude.

[0081] According to some aspects, (with reference to the seventh support member 337) the 3D printed object 300 may also include a second pair of masses (e.g., a fifth mass 337-5 and a sixth mass 337-6) integrally formed along the length of the seventh support member 337, spaced apart from the first pair of masses (e.g., the first mass 337-1 and the second mass 337-2), the second pair of masses configured to vibrate with a second predetermined mode of vibration in response to a second vibration of the 3D printed object 300 at a second predetermined frequency, different from the first predetermined frequency and different from a natural frequency of the 3D printed object 300, where the seventh support member 337 is configured to self-sever from the 3D printed object 300 at or adjacent to the second point 357 (i.e., the distal breakaway point 357) in response to the second vibration at the second predetermined frequency that induces fatigue (e.g., metal fatigue) in the seventh support member 337 at or adjacent to the second point 357.

[0082] According to some aspects, (with reference to the seventh support member 337) the 3D printed object 300 may also include a third pair of masses (e.g., a third mass 337-3 and a fourth mass 337-4) integrally formed along the length of the seventh support member 337, spaced apart from and between the first pair of masses (e.g., the first mass 337-1 and the second mass 337-2) and the second pair of masses (e.g., the fifth mass 337-5 and the sixth mass 337-6), the third pair of masses (e.g., the third mass 337-3 and the fourth mass 337-4) configured to vibrate with a third predetermined mode of vibration in response to a third vibration of the 3D printed object 600 at a third predetermined frequency, different from the first predetermined frequency, the second predetermined frequency, and the natural frequency of the 3D printed object, where the seventh support member 337 is configured to self-sever into two distinct and separate pieces at the intermediate point 307 between the first pair of masses (e.g., the first mass 337-1 and the second mass 337-2) and the second pair of masses (e.g., the fifth mass 337-5 and the sixth mass 337-6) in response to the third vibration at the third predetermined frequency that induces fatigue (e.g., metal fatigue) in the seventh support member 337 at or adjacent to the intermediate point 307.

[0083] According to some aspects, the seventh support member 337 may be a vibration- induced self-severing support member. The self-severing support member may be configured to self-sever from the 3D printed object at or adjacent to the first point 347 in response to the first vibration and in an absence of a mechanical force applied by a tool directly to the support member prior to the self-sever.

[0084] According to some aspects, respective weights of the first pair of masses (e.g., the first mass 337-1 and the second mass 337-2), respective shapes of the first pair of masses, a first distance of a first one (e.g., the first mass 337-1 ) of the first pair of masses from the first point 347, and a second distance of a second one (e.g., the second mass 337-2) of the first pair of masses from the first one (e.g., the first mass 337-1 ) of the first pair of masses determines the first predetermined frequency.

[0085] According to some aspects, the first surface 304 at least one of: overhangs, bridges, or is cantilevered relative to a void (e.g., a space 408, FIG. 4) bounded at opposing sides by at least the first surface 304 and the second surface 310.

[0086] According to some aspects, respective ones of the first pair of masses (e.g., the first mass 337-1 and the second mass 337-2) have at least one of: a polyhedral shape,a cone shape, a pyramid with a non-polygonal base shape, a cylinder shape, a prism with a non-polygonal cross-section shape, a sphere shape, or a hemisphere shape. The preceding list is exemplary and non-limiting.

[0087] According to some aspects, a first cross-section of the seventh support member 337 perpendicular to a longitudinal axis (e.g., the Y-axis in the example of FIG. 3) of the seventh support member 337, excluding locations along the length of the seventh support member 337 occupied by respective ones of the first pair of masses (e.g., the first mass 337-1 and the second mass 337-2), is constant along the longitudinal axis of the seventh support member 337.

[0088] According to some aspects, the fatigue described above may be a fatigue fracture. According to some aspects, the fatigue described above may be a metal fatigue.

[0089] FIG. 4 is an enlarged view of a portion of FIG. 3 with a further enlarged inset view according to some aspects of the disclosure. The enlarged view of the portion of FIG. 3, as depicted in FIG. 4, includes the third support member 333 between the first surface 304 and the center-bottom surface 310-2 according to some aspects of the disclosure. The first mass 333-1 , the second mass 333-2, the third mass 333-3, and the fourth mass 333-4 of the third support member 333 are illustrated. In an enlarged inset view of FIG. 4, the first surface 304, the first mass 333-1 , and the second mass 333-2 are depicted.

[0090] According to the examples described herein, any support member may be designed with a plurality of masses, where the masses are spaced apart from one another and a nearby breakaway point (or breakaway line). By way of example, a numerical model analysis solver (e.g., such as a numerical model analysis solver offered by Ansys of Canonsburg, Pennsylvania) may be used to derive a frequency that would induce a mode of vibration to the third support member 333, such that the first mass 333-1 (for example) would vibrate (e.g., move, flex), yet there would be no or little (e.g., minor, negligible, slight compared to the vibration of the first mass 333-1 ) vibration (e.g., movement, flexure) of the second mass 333-2 (nor of the third mass 333-3 nor the fourth mass 333-4). In FIG. 4, a double-headed arrow with a first arrowhead 402-1 and a second arrowhead 402-2 pointing in opposite directions denotes vibration, while two single-headed arrows with a respective third arrowhead 404-1 and a respective fourth arrowhead 404-2 pointing toward each other denoteslittle or no vibration. The size and length of the various arrows are for illustrative and non-limiting purposes. They are not intended to represent a magnitude of movement (e.g., due to vibration) or a relative comparison of the magnitudes of movement.

[0091] The vibration of the first mass 333-1 is illustrated with exaggeration in the magnified inset of FIG. 4. As depicted in the figure, the frequency that induced the movement of the first mass 333-1 results in the second mass 333-2 essentially remaining motionless. The second mass 333-2 may serve as an effective anchor point for the movement of the first mass 333-1 . The vibration, movement, and flexure of the first mass 333-1 adjacent to the proximal breakaway point 343 causes the third support member 333 to fatigue at, or substantially near, the proximal breakaway point 343. Eventually, due to prolonged vibration at the predetermined frequency, the third support member 333 is severed from the first surface 304 of the body 302 of the 3D printed object 300 at, or substantially at, the proximal breakaway point 343.

[0092] FIG. 5 is the front elevation cross-sectional orthogonal projection of the 3D printed object 300 according to some aspects of the disclosure. In FIG. 5, the 3D printed object 300 is removed from the platen 322 (e.g., a build-plate, a base) (which is not shown to avoid cluttering the drawing of FIG. 5). Essentially, for this example, the point of the first support member 301 that is most distal from the first surface 304 has been separated from the platen 322 and is located in free space in the exemplary illustration of FIG. 5.

[0093] The seven support members shown in FIG. 5 are the same seven support members as shown in FIG. 3, and their detailed descriptions will not be repeated to avoid duplication and for the sake of brevity. Like reference numbers in FIGs. 3, 4, and 5 identify like features. Additionally, as in FIG. 4, a double-headed arrow denotes vibration, while two single-headed arrows pointing toward one another denote little or no vibration.

[0094] In FIG. 5, the body 302 of the 3D printed object 300 is undergoing vibration at a specified predetermined frequency that is different from the natural frequency of the body 302 of the 3D printed object 300. The first support member 331 , the third support member 333, the sixth support member 336, and the seventh support member 337 are shown in simultaneous states of vibration. The simultaneous vibrations of the variously shaped support members and their respective masses at the specified predetermined frequency, while not outside of the scope of the disclosure, may not beobserved in some real-life examples. This conclusion may be drawn from an understanding that one frequency may induce a mode of vibration among a first plurality of support members having the same or substantially similar lengths, with the same or substantially similar masses (each having a predetermined shape, size, and weight), with the same or substantially similar spacings between the masses and a given surface, and with the same or substantially similar relative spacings between the masses themselves. However, this same frequency may not induce the same mode of vibration, or may not induce any mode of vibration, among a second plurality of support members having different characteristics and masses compared to the first plurality of support members.

[0095] Consequently, at least because the first support member 331 , the third support member 333, the sixth support member 336, and / or the seventh support member 337 appear to have at least two different lengths, possibly different mass weights, different spacings between their masses and a given surface, and different relative spacings between the masses themselves, the frequency that induces a desired mode of vibration in the first support member may not induce the same or any mode of vibration in the third support member 333, the sixth support member 336, and / or the seventh support member 337. Nevertheless, to avoid having to provide a plurality of figures, each showing a different vibration at a different end of a plurality of respective support members, FIG. 5 exemplifies all vibrations occurring or not occurring simultaneously.

[0096] However, it will be understood that through the use of, for example, a numerical model analysis solver, respective frequencies (and amplitudes) of vibration, which are different from the natural frequency of the 3D printed object 300, may be determined such that support members having the same characteristics (e.g., length, number of masses, weight and shape of masses, locations of masses from an adjacent surface, locations of masses relative to one another) may all be induced to vibrate at a predetermined mode. All such similar support members induced to a predetermined mode of vibration in response to a respective frequency may be severed from one or both of their breakaway points at substantially the same time in response to vibration- induced fatigue at one or both of their breakaway points.

[0097] In other examples, again through the use of, for example, a numerical model analysis solver, different respective frequencies (and amplitudes) of vibration, which are different from the natural frequency of the 3D printed object 300, may bedetermined such that similar support members having two respective pairs of configured masses, where a configuration of the first pair is different from the configuration of the second pair, may be separately induced to vibrate at two different respective frequencies. Accordingly, a first mass of a first pair of masses adjacent to a distal breakaway point may be induced to vibrate at a first frequency to cause the support member to self-sever from the body 302 of the 3D printed object at or substantially at the distal breakaway point. Subsequently, a second mass of a second pair of the masses adjacent to a proximal breakaway point may be induced to vibrate at a second frequency, different from the first frequency, to cause the support member to be self-severed from the body 302 of the 3D printed object at or substantially at the proximal breakaway point.

[0098] In other examples, again through the use of, for example, a numerical model analysis solver, different respective frequencies (and amplitudes) of vibration, which are different from the natural frequency of the 3D printed object 300, may be determined such that similar support members having three or more respective pairs of configured masses, where a configuration of the first pair, second pair, third pair, etc. is different from any of the other pairs, may be separately induced to vibrate at three or more different respective frequencies. Accordingly, a first mass of a first pair of masses adjacent to a distal breakaway point may be induced to vibrate at a first frequency to cause the support member to be self-severed from the body 302 of the 3D printed object at the distal breakaway point. Subsequently, a first intermediate mass of an intermediate pair of the masses adjacent to an intermediate breakaway point may be induced to vibrate at an intermediate frequency (different from the first frequency) to cause the support member to self-sever at the intermediate breakaway point (e.g., to cut the support member in half). Subsequently, a third mass of a third pair of the masses adjacent to a proximal breakaway point may be induced to vibrate at a third frequency (different from the first and second frequencies) to cause the support member to self-sever from the body 302 of the 3D printed object at the proximal breakaway point. Severing the support member into two or more pieces may facilitate the removal of the two or more pieces of the support member from a relatively inaccessible area (e.g., an area out of which the unbroken support member may not be caused to fall or otherwise be extricated, disengaged, or removed from).

[0099] In general, and as illustrated and described in connection with FIG. 3, 4, and 5, the 3D printed objects described herein may include a first surface 304 of the 3D printed object 300, a second surface 310 (e.g., the working surface 310-1 of the platen 322, the center-bottom surface 310-2, the right-bottom surface 310-3) of the 3D printed object 300 spaced apart from the first surface 304, a space bounded at least between the first surface 304 (e.g., the upper interior surface) and the second surface 310 (e.g., any one or more of the working surface 310-1 of the platen 322, the center-bottom surface 310-2, the right-bottom surface 310-2), a support member (e.g., the first support member 331 , the third support member 333, the fourth support member 334, the fifth support member 335, the sixth support member 336, the seventh support member 337) integrally formed with the first surface 304 at a first point (e.g., any of the proximal breakaway points 341 , 343, 344, 345, 346, 347) coincident with the first surface 304 and the support member and integrally formed with the second surface 310 (e.g., any of the working surface 310-1 of the platen 322, the center-bottom surface 310-2, the right-bottom surface 310-2) at a second point (e.g., any of the distal breakaway points 351 , 353, 354, 355, 356, 357), distal from the first point and coincident with the second surface 310, a first pair of masses (e.g., using the third support member 333 as an example, the first mass 333-1 and the second mass 333- 2, or the third mass 333-3 and the fourth mass 333-4 may be the first pair of masses, respectively) integrally formed along a length of the support member (e.g., the third support member 333), at least one mass of the first pair of masses (e.g., first mass 333-1 or fourth mass 333-4, respectively) configured to vibrate with a first predeterm ined mode of vibration in response to a first vibration of the 3D printed object 300 at a first predetermined frequency, where the support member (e.g., third support member 333) is configured to self-sever from the 3D printed object 300 at or adjacent to the first point (i.e. , the proximal breakaway point 343 or the distal breakaway point 353, respectively) in response to the first vibration, at the first predetermined frequency, that induces (metal) fatigue in the support member (e.g., the third support member 333) at or adjacent to the first point (i.e., the proximal breakaway point 343 or the distal breakaway point 353, respectively).

[0100] Considering the first support member 331 of FIG. 5, a vibration of the first mass 331 -1 , while at least the second mass 331 -2 of the first support member 331 exhibits no or little (e.g., minor, negligible, slight compared to the vibration of the first mass331 -1 ) vibration, is illustrated. The vibration of the first mass 331 -1 is illustrated by the double-headed arrow 371 ; the no or little vibration is illustrated by the pairs of arrows 372 pointing toward each other. The notations of the double-headed arrow and the pair of arrows pointing toward each other are used throughout FIG. 5; however, the reference numbers 371 and 372 are only used in association with the first support member 331 to avoid cluttering the drawing.

[0101] Fatigue of the first support member 331 at the proximal breakaway point 341 is being induced by the vibration of the first mass 331 -1 . The fatigue has not yet caused the first support member 331 to self-sever from the body 302 of the 3D printed object 300 at or adjacent to the proximal breakaway point 341 . However, eventually, the fatigue caused by the vibration of the first mass 331 -1 will result in the severing (the breaking) of the first support member 331 from the body 302 of the 3D printed object 300.

[0102] Considering the second support member 332 of FIG. 5, it is noted that only one mass (a sole mass 332-1 ) is present along the length of the second support member 332. The sole mass 332-1 is positioned at a lengthwise center of the second support member 332 (for exemplary and non-limiting purposes). A vibration (not shown) of the sole mass 332-1 may cause undefined modes of vibration to exist on the second support member 332. At least because only the sole mass 332-1 is utilized in connection with the second support member 332, the second support member 332 may fracture (e.g., break itself into at least two pieces) at any place (where any place is identified with a bracket associated with reference number 502 in FIG. 5) along the length of the second support member 332. The unpredictability of the use of a sole mass 332-1 along the length of the second support member 332 causes the configuration of the second support member 332 in FIG. 5 to be unsatisfactory for at least a purpose of configuring a support member to self-sever from the body 302 of the 3D printed object 300 at a predetermined location (e.g., at the proximal breakaway point 342 and / or at the distal breakaway point 352).

[0103] Considering the third support member 333 of FIG. 5, a vibration of the fourth mass 333-4, while at least the third mass 333-3 of the third support member 333 exhibits no or little vibration, is illustrated. Fatigue of the third support member 333 at the distal breakaway point 353 may be induced by the fatigue caused by the vibration of the fourth mass 333-4. The fatigue may cause the third support member 333 to self-sever from the body 302 of the 3D printed object 300 at or adjacent to the distal breakaway point 353.

[0104] Considering the fourth support member 334 and the fifth support member 335 of FIG. 5. All masses of these two support members are not vibrating. Whatever frequency is being applied to the 3D printed object does not induce vibration in any of the masses of these two support members. Two single-headed arrows pointing toward each other at each of the four masses of these two support members are omitted to avoid cluttering the drawing. The lack of vibration of the fourth support member 334 and the fifth support member 335 and the non-perpendicularity of the fourth support member 334 and the fifth support member 335 is purely coincidental and not intended to imply that any lack of perpendicularity will suppress or eliminate vibration in the fourth support member 334 and the fifth support member 335.

[0105] Considering the sixth support member 336 of FIG. 5, in an instant captured in FIG. 5, a prior vibration of the fourth mass 336-4 already occurred while at least the third mass 336-3 of the sixth support member 336 exhibited no or little vibration compared to the prior vibration of the fourth mass 336-4. The fatigue of the sixth support member 336 at the distal breakaway point 356 previously caused the sixth support member 336 to self-sever from the body 302 of the 3D printed object 300 at or adjacent to the distal breakaway point 356. The severing is noted in the area of the distal breakaway point 356 surrounded by a circle. Presently, a vibration of the first mass 336-1 while at least the second mass 336-2 of the sixth support member 336 exhibits no or little vibration is illustrated. Fatigue of the sixth support member 336 at the proximal breakaway point 346 induced by the vibration of the first mass 336-1 has just caused the sixth support member 336 to self-sever from the body 302 of the 3D printed object 300 at or adjacent to the proximal breakaway point 346. The severing is noted in the area of the proximal breakaway point 346 surrounded by a circle. The sixth support member 336, now severed at both ends from the 3D printed object 300, is free to fall to the bottom of the 3D printed object 300 and be subsequently removed through the opening that was initially covered by the working surface 310-1 of the platen 322 (both of which are not illustrated in FIG. 5 to avoid cluttering the drawing). However, it may be difficult to remove the long sixth support member 336. Accordingly, in the following example, the seventh support member is fractured (e.g., broken in two) into two distinct and separate pieces. Removal of the two distinct and separate piecesthat are half the length of the unfractured sixth support member 336 may be easier than removal of the unfractured sixth support member 336.

[0106] Considering the seventh support member 337 of FIG. 5, which includes three pairs of masses, a first pair of masses including the first mass 337-1 and the second mass 337-2, a second pair of masses including the first intermediate mass 337-3 and the second intermediate mass 337-4, and a third pair of masses including the fifth mass 337-5 and the sixth mass 337-6. A vibration applied to the 3D printed object does not cause the first pair of masses to vibrate and does not cause the second pair of masses to vibrate. However, the vibration does cause the first intermediate mass 337-3 to vibrate, while at least the second intermediate mass 337-4 exhibits no or little vibration (e.g., compared to the vibration of the first intermediate mass 337-3), as illustrated. Fatigue of the seventh support member 337 at the intermediate point 307 is being induced by the vibration of the first intermediate mass 337-3. The fatigue has not yet caused the seventh support member 337 to fracture or sever into two distinct and separate halves. After the severing occurs, the 3D printed object 300 may be vibrated at a first frequency that causes the upper half of the seventh support member 337 to self-sever from the 3D printed object 300 at the proximal breakaway point 347. Similarly, after (or before) the severing of the upper half of the seventh support member 337, the 3D printed object 300 may be vibrated at a second frequency that causes the lower half of the seventh support member 337 to self-sever from the 3D printed object 300 at the distal breakaway point 357. In some examples, a single frequency may be used to self-sever both the upper and lower halves of the seventh support member 337 from their respective proximal breakaway point 347 and distal breakaway point 357 (as each half is fixed to the 3D printed object at only one point respectively following the severing of the seventh support member 337 into two halves at the intermediate point 307).

[0107] FIG. 6 is a perspective view of one example of a 3D printed object 600 that includes a support member 601 that is configured as a wall or web with an integral first mass 601 -1 and an integral second mass 601 -2 according to some aspects of the disclosure. The wall or web is positioned in a space between, and integral with, a first surface 604 (e.g., an upper surface) of an upper part of a 3D printed object 600 and a spaced apart second surface 606 (e.g., a lower surface spaced apart from the firstsurface 604) of the 3D printed object 600. The wall or web is illustrated with one pair of masses; however, this is for ease of illustration and not limitation.

[0108] According to some aspects, the three-dimensional (3D) printed object 600 may include a first surface 604 of the 3D printed object 600, a second surface 606 of the 3D printed object 600 spaced apart from the first surface 604, a space 608 bounded at least between the first surface 604 and the second surface 606, a support member 601 , integrally formed with the first surface 604 at a first point 610 (e.g., a proximal breakaway point) coincident with the first surface 604 and the support member 601 and integrally formed with the second surface 606 at a second point 612 (e.g., a distal breakaway point), distal from the first point 610 and coincident with the second surface 606, a first pair of masses (e.g., the integral first mass 601 -1 and the integral second mass 601 -2), integrally formed along the length of the support member 601 , at least one of the first pair of masses (e.g., the integral first mass 601 -1 ) configured to vibrate with a first predetermined mode of vibration in response to a first vibration of the 3D printed object 300 at a first predetermined frequency, where the support member 601 is configured to self-sever from the 3D printed object 600 at or adjacent to the first point 610 in response to the first vibration, at the first predetermined frequency, that induces fatigue (e.g., metal fatigue, fatigue fracture, structural fatigue) in the support member 601 at or adjacent to the first point 610.

[0109] In some examples, the first predetermined frequency is different from a natural frequency of the 3D printed object. The first surface 604 at least one of: overhangs the spaced apart second surface 606, bridges the spaced apart second surface 606, or is cantilevered above the spaced apart second surface 606. The respective weights of the first pair of masses, respective shapes of the first pair of masses, a first distance of a first one of the first pair of masses from the first point 610, and a second distance of a second one of the first pair of masses from the first one of the first pair of masses may be set to induce the vibration at the first predetermined frequency. Respective ones of the first pair of masses may have at least one of: a polyhedral shape, a cone shape, a pyramid with a non-polygonal base shape, a cylinder shape, a prism with a non-polygonal cross-section shape, a sphere shape, or a hemisphere shape. A first cross-section of the support member 601 perpendicular to a longitudinal axis of the support member 601 , excluding locations along the length of the support member occupied by respective ones of the first pair of masses, may be constant along thelongitudinal axis of the support member 601. Each of the aspects of some examples described above are provided for exemplary and non-limiting purposes. All lists provided above are provided for exemplary and non-limiting purposes.

[0110] According to some examples, the 3D printed object 600 may also include a second pair of masses (not shown) integrally formed along the length of the support member 601 , spaced apart from the first pair of masses, the second pair of masses configured to vibrate with a second predetermined mode of vibration in response to a second vibration of the 3D printed object 600 at a second predetermined frequency, different from the first predetermined frequency and different from a natural frequency of the 3D printed object 600, where the support member 601 is configured to self-sever from the 3D printed object 600 at or adjacent to the second point 612 in response to the second vibration at the second predetermined frequency that induces (metal) fatigue in the support member 601 at or adjacent to the second point 612.

[0111] According to still another example, the 3D printed object 600 may also include a third pair of masses (not shown) integrally formed along the length of the support member 601 , spaced apart from and between the first pair of masses and the second pair of masses, the third pair of masses configured to vibrate with a third predetermined mode of vibration in response to a third vibration of the 3D printed object 600 at a third predetermined frequency, different from the first predetermined frequency, the second predetermined frequency, and the natural frequency of the 3D printed object, where the support member 601 is configured to self-sever into two distinct and separate pieces at an intermediate point between the first pair of masses and the second pair of masses in response to the third vibration at the third predetermined frequency that induces (metal) fatigue in the support member at or adjacent to the intermediate point.

[0112] According to some aspects, the support member 601 may be a vibration-induced self-severing support member configured to self-sever from the 3D printed object at or adjacent to the first point in response to the first vibration and in an absence of any mechanical force applied by a tool directly to the support member prior to the self- sever.

[0113] FIG. 7 is a flow chart illustrating an example process 700 (e.g., a method) of manufacturing a 3D printed object according to some aspects of the disclosure. As described below, some or all illustrated features may be omitted in a particularimplementation within the scope of the present disclosure, and some illustrated features may not be required for all implementations. In some examples, the process 700 may be carried out, for example, using a 3D printer and a vibration inducing device (e.g., a vibration table). In some examples, the process 700 may be carried out by any suitable apparatus or means for carrying out the functions or algorithm described below.

[0114] At block 702, a 3D printer may print a first surface of the 3D printed object.

[0115] At block 704, the 3D printer may print a second surface of the 3D printed object, spaced apart from the first surface. According to some aspects, the first surface may at least one of: overhang, bridge, or be cantilevered relative to a void (e.g., a space 408, FIG. 4) bounded at opposing sides by at least the first surface and the second surface.

[0116] At block 706, the 3D printer may print a support member between the first surface and the second surface. The support member may be integrally formed with the first surface at a first point coincident with the first surface and integrally formed with the second surface at a second point, distal from the first point and coincident with the second surface. According to some examples, a first cross-section of the support member perpendicular to a longitudinal axis of the support member, excluding locations along the length of the support member occupied by respective ones of the first pair of masses, may be constant along the longitudinal axis of the support member.

[0117] At block 708, the 3D printer may print a first pair of masses integrally formed along a length of the support member, at least one of the first pair of masses configured to vibrate with a first predetermined mode of vibration in response to a first vibration of the 3D printed object at a first predetermined frequency. According to some examples, the first predetermined frequency may be different from a natural frequency of the 3D printed object.

[0118] According to some examples, the at least one of the first pair of masses may be a first mass and another one of the first pair of masses may be a second mass. The first predetermined mode of vibration may be configured to vibrate the first mass with a first amplitude and to vibrate the second mass with a second amplitude, less than the first amplitude. In some examples, the second amplitude may be at least two to twenty times less or, more specifically, four to fifteen times less, or even morespecifically, six to ten times less than the first amplitude. In some examples, the second amplitude may be zero (i.e. , the second mass may not vibrate).

[0119] According to some aspects, the respective weights of the first pair of masses, respective shapes of the first pair of masses, a first distance of a first one of the first pair of masses from the first point, and a second distance of a second one of the first pair of masses from the first one of the first pair of masses, may determine the first predetermined frequency. That is, through the selection of the respective weights of the first pair of masses, respective shapes of the first pair of masses, a first distance of a first one of the first pair of masses from the first point, and a second distance of a second one of the first pair of masses from the first one of the first pair of masses, the 3D printed object, and more specifically the support member, may be configured to vibrate in the first predetermined mode at the first predetermined frequency. In some examples, respective ones of the first pair of masses may have at least one of: a polyhedral shape, a cone shape, a pyramid with a non-polygonal base shape, a cylinder shape, a prism with a non-polygonal cross-section shape, a sphere shape, or a hemisphere shape. The preceding list is exemplary and non-limiting.

[0120] Although illustrated in FIG. 7 as occurring in parallel, those persons having ordinary skill in the art will recognize that the processes described in blocks 702, 704, 706, and 708 may occur sequentially, simultaneously, and / or in parallel. Using FIG. 3 as an example, a 3D printer might first print the second surface 310 of the 3D printed object and, because the seventh support member 337 is integral to the second surface 310, may continue with the printing of the seventh support member 337. Of course, the first pair of masses (e.g., first mass 337-1 and second mass 337-2) are integral to the seventh support member 337, and therefore their fabrication would occur while the support member is being manufactured (e.g., 3D printed). Still further, the first surface 304 is integrally coupled to the seventh support member 337, such that the 3D printer may continue with the printing of the first surface 304 as it concludes the printing of the seventh support member 337.

[0121] At block 710, once the manufacture of the 3D printed object in the 3D printer is completed, the 3D printed object may be removed from the 3D printer. Some actions may be performed (not shown) after removal of the 3D printed object from the 3D printer (e.g., removing unfused powder if the 3D printer was a type that manufactured the 3D printed object in a powder bed, inspection, etc.).

[0122] At block 712, the 3D printed object may be vibrated at the first predetermined frequency, where the support member (e.g., the seventh support member 337, FIG. 3) is configured to self-sever from the 3D printed object (e.g., 3D printed object 300, FIG. 3) at or adjacent to the first point (e.g., first point 347, the proximal breakaway point 347, FIG. 3) in response to the vibrating at the first predetermined frequency. According to some aspects, the support member may be a vibration-induced selfsevering support member configured to self-sever from the 3D printed object at or adjacent to the first point in response to the first vibration and in an absence of any mechanical force applied by a tool directly to the support member prior to the self- sever.

[0123] The following provides an overview of aspects of the present disclosure.

[0124] Aspect 1 : A three-dimensional (3D) printed object, including: a first surface of the 3D printed object; a second surface of the 3D printed object, spaced apart from the first surface; a support member between the first surface and the second surface is integrally formed with the first surface at a first point coincident with the first surface and is integrally formed with the second surface at a second point, distal from the first point and coincident with the second surface; and a first pair of masses integrally formed along a length of the support member, at least one of the first pair of masses configured to vibrate with a first predetermined mode of vibration in response to a first vibration of the 3D printed object at a first predetermined frequency, wherein the support member is configured to self-sever from the 3D printed object at or adjacent to the first point in response to the first vibration at the first predetermined frequency, which induces fatigue in the support member at or adjacent to the first point.

[0125] Aspect 2: The 3D printed object of aspect 1 , wherein the first predetermined frequency is different from a natural frequency of the 3D printed object.

[0126] Aspect 3: The 3D printed object of aspect 1 or aspect 2, wherein the at least one of the first pair of masses is a first mass and another one of the first pair of masses is a second mass, and the first predetermined mode of vibration is configured to vibrate the first mass with a first amplitude and to vibrate the second mass with a second amplitude, less than the first amplitude.

[0127] Aspect 4: The 3D printed object of any of aspects 1 through 3, wherein the second amplitude is at least two to twenty times less or, more specifically, four tofifteen times less, or even more specifically, six to ten times less than the first amplitude.

[0128] Aspect 5: The 3D printed object of any of aspects 1 through 4, further including a second pair of masses integrally formed along the length of the support member, spaced apart from the first pair of masses, the second pair of masses configured to vibrate with a second predetermined mode of vibration in response to a second vibration of the 3D printed object at a second predetermined frequency, different from the first predetermined frequency and different from a natural frequency of the 3D printed object, wherein the support member is configured to self-sever from the 3D printed object at or adjacent to the second point in response to the second vibration at the second predetermined frequency that induces fatigue in the support member at or adjacent to the second point.

[0129] Aspect 6: The 3D printed object of any of aspects 1 through 5, further including a third pair of masses integrally formed along the length of the support member, spaced apart from and between the first pair of masses and the second pair of masses, the third pair of masses configured to vibrate with a third predetermined mode of vibration in response to a third vibration of the 3D printed object at a third predetermined frequency, different from the first predetermined frequency, the second predetermined frequency, and the natural frequency of the 3D printed object, wherein the support member is configured to self-sever into two distinct pieces at an intermediate point between the first pair of masses and the second pair of masses in response to the third vibration at the third predetermined frequency that induces fatigue in the support member at or adjacent to the intermediate point.

[0130] Aspect 7: The 3D printed object of any of aspects 1 through 6, wherein the support member is a vibration-induced self-severing support member configured to self-sever from the 3D printed object at or adjacent to the first point in response to the first vibration and in an absence of any mechanical force applied by a tool directly to the support member prior to the self-sever.

[0131] Aspect 8: The 3D printed object of any of aspects 1 through 7, wherein respective weights of the first pair of masses, respective shapes of the first pair of masses, a first distance of a first one of the first pair of masses from the first point, and a second distance of a second one of the first pair of masses from the first one of the first pair of masses determines the first predetermined frequency.

[0132] Aspect 9: The 3D printed object of any of aspects 1 through 8, wherein the first surface at least one of: overhangs, bridges, or is cantilevered relative to a void bounded at opposing sides by at least the first surface and the second surface.

[0133] Aspect 10: The 3D printed object of any of aspects 1 through 9, wherein respective ones of the first pair of masses have at least one of: a polyhedral shape, a cone shape, a pyramid with a non-polygonal base shape, a cylinder shape, a prism with a non-polygonal cross-section shape, a sphere shape, or a hemisphere shape.

[0134] Aspect 11 : The 3D printed object of any of aspects 1 through 10, wherein a first cross-section of the support member perpendicular to a longitudinal axis of the support member, excluding locations along the length of the support member occupied by respective ones of the first pair of masses, is constant along the longitudinal axis of the support member.

[0135] Aspect 12: The 3D printed object of aspect 1 , wherein the fatigue is a fatigue fracture.

[0136] Aspect 13: The 3D printed object of aspect 1 , wherein the fatigue is a metal fatigue.

[0137] Aspect 14: A method of manufacturing a three-dimensional (3D) printed object, including: printing, in a 3D printer, a first surface of the 3D printed object; printing, in the 3D printer, a second surface of the 3D printed object, spaced apart from the first surface; printing, in the 3D printer, a support member between the first surface and the second surface is integrally formed with the first surface at a first point coincident with the first surface and is integrally formed with the second surface at a second point, distal from the first point and coincident with the second surface; printing, in the 3D printer, a first pair of masses integrally formed along a length of the support member, at least one of the first pair of masses configured to vibrate with a first predetermined mode of vibration in response to a first vibration of the 3D printed object at a first predetermined frequency; removing the 3D printed object from the 3D printer; and vibrating, after the removing, the 3D printed object at the first predetermined frequency, wherein the support member is configured to self-sever from the 3D printed object at or adjacent to the first point in response to the vibrating at the first predetermined frequency.

[0138] Aspect 15: The method of manufacturing the 3D printed object of aspect 14, wherein the first predetermined frequency is different from a natural frequency of the 3D printed object.

[0139] Aspect 16: The method of manufacturing the 3D printed object of aspect 14 or 15, wherein the at least one of the first pair of masses is a first mass and another one of the first pair of masses is a second mass, and the first predetermined mode of vibration is configured to vibrate the first mass with a first amplitude and to vibrate the second mass with a second amplitude, less than the first amplitude.

[0140] Aspect 17: The method of manufacturing the 3D printed object of any of aspects 14 through 16, wherein the second amplitude is at least two to twenty times less or, more specifically, four to fifteen times less, or even more specifically, six to ten times less than the first amplitude.

[0141] Aspect 18: The method of manufacturing the 3D printed object of any of aspects14 through 17, wherein the support member is a vibration-induced self-severing support member configured to self-sever from the 3D printed object at or adjacent to the first point in response to the first vibration and in an absence of any mechanical force applied by a tool directly to the support member prior to the self-sever.

[0142] Aspect 19: The method of manufacturing the 3D printed object of any of aspects 14 through 18, wherein respective weights of the first pair of masses, respective shapes of the first pair of masses, a first distance of a first one of the first pair of masses from the first point, and a second distance of a second one of the first pair of masses from the first one of the first pair of masses determines the first predetermined frequency.

[0143] Aspect 20: The method of manufacturing the 3D printed object of aspect 14, wherein the fatigue is a fatigue fracture.

[0144] One or more of the components, steps, features, and / or functions illustrated in FIGs. 1 -7 may be rearranged and / or combined into a single component, step, feature, or function or embodied in several components, steps, or functions. Additional elements, components, steps, and / or functions may also be added without departing from novel features disclosed herein. The apparatus, devices, and / or components illustrated in FIGs. 1 -7 may be configured to perform one or more of the methods, features, or steps described herein. The novel algorithms described herein may also be efficiently implemented in software and / or embedded in hardware.

[0145] It is to be understood that the specific order or hierarchy of steps in the methods disclosed is an illustration of exemplary processes. Based on design preferences, it is understood that the specific order or hierarchy of steps in the methods may be rearranged. The method claims present elements of the various steps in a sample order and are not meant to be limited to the specific order or hierarchy presented unless specifically recited therein.

[0146] The previous description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to these aspects will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other aspects. Thus, the claims are not intended to be limited to the aspects shown herein but are to be accorded the full scope consistent with the language of the claims, wherein the reference to an element in the singular is not intended to mean “one and only one” unless specifically so stated, but rather “one or more.” Unless specifically stated otherwise, the term “some” refers to one or more.

[0147] Various modifications to the examples described in this disclosure may be readily apparent to persons having ordinary skill in the art, and the generic principles defined herein may be applied to other examples without departing from the spirit or scope of this disclosure. Thus, the claims are not intended to be limited to the examples shown herein but are to be accorded the widest scope consistent with this disclosure, the principles, and the novel features disclosed herein.

[0148] Additionally, various features that are described in this specification in the context of separate examples can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple examples separately or in any suitable subcombination. As such, although features may be described above as acting in particular combinations, and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

[0149] Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order or that all illustrated operations be performed to achieve desirable results. Further, the drawings may schematicallydepict one or more example processes in the form of a flowchart or flow diagram. However, other operations that are not depicted can be incorporated into the schematically illustrated example processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the illustrated operations. In some circumstances, multitasking and parallel processing may be advantageous.

Claims

CLAIMSWhat is claimed is:1 . A three-dimensional (3D) printed object, comprising: a first surface of the 3D printed object; a second surface of the 3D printed object, spaced apart from the first surface; a support member between the first surface and the second surface is integrally formed with the first surface at a first point coincident with the first surface and is integrally formed with the second surface at a second point, distal from the first point and coincident with the second surface; and a first pair of masses integrally formed along a length of the support member, at least one of the first pair of masses configured to vibrate with a first predetermined mode of vibration in response to a first vibration of the 3D printed object at a first predetermined frequency, wherein the support member is configured to self-sever from the 3D printed object at or adjacent to the first point in response to the first vibration at the first predetermined frequency, which induces fatigue in the support member at or adjacent to the first point.

2. The 3D printed object of claim 1 , wherein the first predetermined frequency is different from a natural frequency of the 3D printed object.

3. The 3D printed object of claim 1 , wherein the at least one of the first pair of masses is a first mass and another one of the first pair of masses is a second mass, and the first predetermined mode of vibration is configured to vibrate the first mass with a first amplitude and to vibrate the second mass with a second amplitude, less than the first amplitude.

4. The 3D printed object of claim 3, wherein the second amplitude is at least two to twenty times less or, more specifically, four to fifteen times less, or even more specifically, six to ten times less than the first amplitude.

5. The 3D printed object of claim 1 , further comprising: a second pair of masses integrally formed along the length of the support member, spaced apart from the first pair of masses, the second pair of masses configured to vibrate with a second predetermined mode of vibration in response to a second vibration of the 3D printed object at a second predetermined frequency, different from the first predetermined frequency and different from a natural frequency of the 3D printed object, wherein the support member is configured to self-sever from the 3D printed object at or adjacent to the second point in response to the second vibration at the second predetermined frequency that induces fatigue in the support member at or adjacent to the second point.

6. The 3D printed object of claim 5, further comprising: a third pair of masses integrally formed along the length of the support member, spaced apart from and between the first pair of masses and the second pair of masses, the third pair of masses configured to vibrate with a third predetermined mode of vibration in response to a third vibration of the 3D printed object at a third predetermined frequency, different from the first predetermined frequency, the second predetermined frequency, and the natural frequency of the 3D printed object, wherein the support member is configured to self-sever into two distinct pieces at an intermediate point between the first pair of masses and the second pair of masses in response to the third vibration at the third predetermined frequency that induces fatigue in the support member at or adjacent to the intermediate point.

7. The 3D printed object of claim 1 , wherein the support member is a vibration- induced self-severing support member configured to self-sever from the 3D printed object at or adjacent to the first point in response to the first vibration and in an absence of any mechanical force applied by a tool directly to the support member prior to the self-sever.

8. The 3D printed object of claim 1 , wherein respective weights of the first pair of masses, respective shapes of the first pair of masses, a first distance of a first one of the first pair of masses from the first point, and a second distance of a second one of the first pair of masses from the first one of the first pair of masses determines the first predetermined frequency.

9. The 3D printed object of claim 1 , wherein the first surface at least one of: overhangs, bridges, or is cantilevered relative to a void bounded at opposing sides by at least the first surface and the second surface.

10. The 3D printed object of claim 1 , wherein respective ones of the first pair of masses have at least one of: a polyhedral shape, a cone shape, a pyramid with a non-polygonal base shape, a cylinder shape, a prism with a non-polygonal cross-section shape, a sphere shape, or a hemisphere shape.11 . The 3D printed object of claim 1 , wherein a first cross-section of the support member perpendicular to a longitudinal axis of the support member, excluding locations along the length of the support member occupied by respective ones of the first pair of masses, is constant along the longitudinal axis of the support member.

12. The 3D printed object of claim 1 , wherein the fatigue is a fatigue fracture.

13. The 3D printed object of claim 1 , wherein the fatigue is a metal fatigue.

14. A method of manufacturing a three-dimensional (3D) printed object, comprising: printing, in a 3D printer, a first surface of the 3D printed object; printing, in the 3D printer, a second surface of the 3D printed object, spaced apart from the first surface; printing, in the 3D printer, a support member between the first surface and the second surface, the support member is integrally formed with the first surface at a first point coincident with the first surface and is integrally formed with the second surface at a second point, distal from the first point and coincident with the second surface; printing, in the 3D printer, a first pair of masses integrally formed along a length of the support member, at least one of the first pair of masses configured to vibrate with a first predetermined mode of vibration in response to a first vibration of the 3D printed object at a first predetermined frequency; removing the 3D printed object from the 3D printer; andvibrating, after the removing, the 3D printed object at the first predetermined frequency, wherein the support member is configured to self-sever from the 3D printed object at or adjacent to the first point in response to the vibrating at the first predetermined frequency.

15. The method of claim 14, wherein the first predetermined frequency is different from a natural frequency of the 3D printed object.

16. The method of claim 14, wherein the at least one of the first pair of masses is a first mass and another one of the first pair of masses is a second mass, and the first predetermined mode of vibration is configured to vibrate the first mass with a first amplitude and to vibrate the second mass with a second amplitude, less than the first amplitude.

17. The method of claim 16, wherein the second amplitude is at least two to twenty times less or, more specifically, four to fifteen times less, or even more specifically, six to ten times less than the first amplitude.

18. The method of claim 14, wherein the support member is a vibration-induced selfsevering support member configured to self-sever from the 3D printed object at or adjacent to the first point in response to the first vibration and in an absence of any mechanical force applied by a tool directly to the support member prior to the self-sever.

19. The method of claim 14, wherein respective weights of the first pair of masses, respective shapes of the first pair of masses, a first distance of a first one of the first pair of masses from the first point, and a second distance of a second one of the first pair of masses from the first one of the first pair of masses determines the first predetermined frequency.

20. The method of claim 14, wherein the fatigue is a fatigue fracture.

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