3D Build Carrier Sheet for Easier Part Separation
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Solution Overview
Problem
The existing methods for additive manufacturing of three-dimensional objects require cumbersome and time-consuming post-processing to separate the object from the carrying element, which involves sawing and surface treatment to meet defined object requirements.
Innovation Solution
The method employs a detachably connected foil- or sheet-like carrying element that forms part of the object, allowing for simplified separation and reduced post-processing by using a carrying unit with connection means, support elements, and a suction unit to maintain the carrying element's stability and facilitate detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the object is additively built on a carrying element using conventional methods, then the object can be manufactured with defined geometry and material properties, but the object becomes bonded to the carrying element requiring cumbersome separation and post-processing
Solution Approach 1:
The carrying element is divided into a modular structure consisting of a carrying unit and a detachable carrying element. This segmentation allows the object to be built on a separate carrying element that can be easily detached after manufacturing, eliminating the need for cumbersome separation and post-processing while maintaining manufacturing precision during the building process.
Solution Approach 2:
The carrying element is pre-configured with connection means (such as magnets, clips, or interlocking features) that enable easy attachment and detachment. This preliminary preparation of the carrying element allows for seamless integration during manufacturing and effortless separation afterward, resolving the contradiction between maintaining manufacturing precision and reducing post-processing effort.
2Reliability
If the object is strongly bonded to the carrying element during additive manufacturing, then manufacturing stability and precision are improved, but separation becomes difficult and time-consuming
Solution Approach 1:
The connection between the carrying element and carrying unit is made dynamic rather than static. The carrying element can be firmly attached during manufacturing to ensure stability and precision, then easily detached afterward. This dynamic connection system allows the bond strength to be temporarily high during manufacturing and easily reversible afterward, resolving the contradiction between manufacturing reliability and separation time.
Solution Approach 2:
An intermediary connection mechanism (such as magnetic attraction, mechanical clips, or adhesive layers) is introduced between the carrying element and carrying unit. This intermediary provides strong holding force during manufacturing to ensure stability, but allows for easy separation when needed, thus resolving the contradiction between manufacturing reliability and separation time.
3Stability of the object's composition
If a rigid carrying element is used to support the object during manufacturing, then structural stability is improved, but the carrying element cannot be easily detached without affecting object surface quality
Solution Approach 1:
The carrying element is segmented into a rigid support structure and a detachable surface-contact portion. The rigid portion provides structural stability during manufacturing, while the detachable portion can be easily removed without affecting the object's surface quality. This segmentation resolves the contradiction between structural stability and surface quality preservation.
Solution Approach 2:
Different portions of the carrying element have different properties: the main body is rigid for structural stability, while the contact surface with the object is designed for easy detachment. This local differentiation of properties allows the carrying element to provide structural support during manufacturing while enabling easy separation that preserves object surface quality, resolving the contradiction between stability and surface quality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach eliminates the need for sawing and subsequent surface treatment, reducing post-processing efforts and ensuring the object's surface quality is maintained without additional processing.
Implementation Method 1
selective layerwise consolidation of layers of a powdered build material which can be consolidated by means of an energy source, e.g. an energy beam, in particular a laser beam
Implementation Method 2
selective irradiation and consolidation of the layers of build material corresponds to the cross-section of the object to be built
Implementation Method 3
a suction unit (17) adapted to suck excess build material (3) out of the recess (15)
Data Source
Figure 1
Figure 2~3
AI summary
Method for additively manufacturing of three-dimensional objects (2) by means of successive layerwise selective irradiation and consolidation of layers of a build material (3) which can be consolidated by means of an energy source, wherein a carrying unit (5) is provided that is adapted to carry the object (2) to be built, wherein at least one foil- or sheet-like carrying element (7) is detachably connected with the carrying unit (5), wherein the carrying element (7) provides a surface (10) on which the object (2) is additively built, wherein at least one part of the carrying element (7) is part of at least one object (2) to be built.