3D Printed Components with Auxiliary Structures for Automated Extraction
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Solution Overview
Problem
Existing three-dimensional printing methods face challenges in safely and efficiently removing completed components from loose particulate material, particularly for small or filigree structures, as they are prone to damage during manual extraction and cannot be automated due to lack of support structures.
Innovation Solution
The method involves constructing an auxiliary structure alongside the components during the printing process, which extends beyond the component dimensions, allowing for easier handling and potential interconnection of multiple components, and can be formed from the same material as the components, facilitating automated removal and post-processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual extraction method is used to remove components from powder bed, then operator can visually locate and handle components, but small and filigree components are damaged by suction nozzle and operator error
Solution Approach 1:
The patent introduces an extractor device with a protective cage structure that acts as an intermediary between the suction nozzle and the components. The cage allows the suction nozzle to remove powder while protecting small and filigree components from direct contact with the nozzle, preventing damage during the extraction process
Solution Approach 2:
The patent implements preliminary actions by first removing loose powder from the build plate surface before extracting components, and by designing the extractor to approach components from a safe distance. The protective cage is positioned in advance to shield components during the powder removal process
2Productivity
If automated removal is implemented without auxiliary structures, then productivity increases, but components cannot be safely handled or positioned
Solution Approach 1:
The patent segments the component removal process into distinct phases: powder removal, component exposure, and component extraction. The extractor device is designed with separate functional zones including a protective cage for powder removal and a gripping mechanism for component extraction, enabling automated operation while maintaining handling capability
Solution Approach 2:
The extractor device serves as an automated intermediary that bridges the gap between the build plate and component removal. It automatically positions itself, removes protective powder, and extracts components without human intervention, achieving both automation and safe handling
3Stability of the object's composition
If components are embedded in loose particulate material for support, then structural stability during printing is maintained, but components become invisible and difficult to locate
Solution Approach 1:
The patent extracts the protective powder material from around the components using a suction nozzle equipped with a protective cage. This removal action exposes the completed components on the build plate, making them visible and locatable while the cage protects against damage during extraction
4Loss of substance
If extractor is used to remove loose particulate material, then powder clearance is achieved, but components are damaged by suction nozzle contact
Solution Approach 1:
The protective cage structure acts as an intermediary barrier between the suction nozzle and the components. It allows the nozzle to effectively remove loose powder material while physically blocking direct contact between the nozzle and the components, preventing damage
Solution Approach 2:
The protective cage is designed as a thin-walled structure that is sufficiently transparent to allow suction of powder through or around it, yet robust enough to protect components from mechanical contact with the nozzle
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 enables safe and efficient handling and automated removal of components, reducing the risk of damage and simplifying the process, allowing for simultaneous handling and processing of multiple components, and automating the removal and cleaning operations.
Implementation Method 1
a binder material is selectively printed on the particulate material, using a print head. The particle area onto which the binder is printed sticks together and solidifies under the influence of the binder
Implementation Method 2
selective laser sintering or electron beam sintering, in which a loose particulate material is also deposited in layers and selectively solidified with the aid of a controlled physical radiation source
Implementation Method 3
selective laser sintering or electron beam sintering, in which a loose particulate material is also deposited in layers and selectively solidified with the aid of a controlled physical radiation source
Data Source
AI summary
The present invention relates to articles prepared using a three-dimensional printing method, an auxiliary structure being additionally formed beyond an extension of the one or more components during the construction of components. The invention also relates to an auxiliary structure for components produced by means of three-dimensional printing methods, the auxiliary structure being constructed along with the component and extending beyond a dimension of the one or more components.