3D Printed Internal Geometry for Reduced Support Removal
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Solution Overview
Problem
Additive manufacturing often requires support structures that are difficult to remove, leading to inefficiencies, potential damage to the object, and aesthetic or functional issues due to residual fragments.
Innovation Solution
Methods for modifying digital representations of objects to reduce or eliminate internal support structures, allowing for objects to be printed without internal supports or with supports that can be easily removed without residue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If support structures are added during additive manufacturing to secure the object and support unstable features, then printing accuracy and stability are improved, but the complexity of support structure removal increases and residual fragments remain
Solution Approach 1:
The support structure is divided into a main body portion and a discrete breakage portion. The breakage portion is designed to be separable from the main body, allowing it to be easily removed after printing. This segmentation enables the support to provide necessary printing stability while facilitating simple post-processing removal without leaving residual fragments on the object.
Solution Approach 2:
The breakage portion is extracted as a separate, removable component from the support structure. This extracted portion can be easily detached or broken off after the printing process, eliminating the need for complex removal procedures and preventing residual fragments from remaining on the final object.
2Stability of the object's composition
If support structures are used to stabilize internal portions during printing, then structural stability is improved, but the difficulty of removing internal supports increases
Solution Approach 1:
The support structure is segmented into a stable main body that remains during printing and a removable breakage portion that can be easily extracted afterward. This segmentation allows the internal support to provide necessary structural stability during the printing process while enabling simple removal without complex tools or procedures.
Solution Approach 2:
The support structure is pre-designed with a breakage portion that is intentionally created to be easily removable. This preliminary design feature anticipates the post-printing removal need, making the support structure inherently easy to remove after serving its stabilizing function during printing.
3Reliability
If manual removal of support structures is performed, then complete removal is achieved, but time consumption and labor costs increase
Solution Approach 1:
By segmenting the support structure into a main body and a breakage portion, the removal process becomes significantly faster and less labor-intensive. The breakage portion can be quickly snapped or broken off without requiring manual tools or extensive time, while still achieving complete removal with no residual fragments remaining on the object.
Data Source
AI summary
Methods and systems for additive manufacturing of objects are provided. In some embodiments, a method includes receiving a digital representation of an object to be fabricated via an additive manufacturing process; identifying an internal portion of the object that would be unstable during the additive manufacturing process without an internal support structure, based on the digital representation; modifying the digital representation of the object to remove at least part of the internal portion; and generating instructions for fabricating the object via the additive manufacturing process, based on the modified digital representation.