3D-Printed Part Support Removal with Rotational Liquid Flow
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Solution Overview
Problem
Existing support removal systems for 3D printed parts are inefficient and require manual adjustments for various parts, leading to inefficiency and potential damage due to uncontrolled movement and collisions.
Innovation Solution
A support removal machine that automatically adjusts to changing conditions using a combination of liquid flow, heat, and ultrasonic radiation, maintaining the part's position with manifolds creating a rotational flow and using ultrasonic transducers for enhanced support removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual adjustment is used for various parts, then the system can handle different part types, but the operator must spend time adjusting parameters such as heat, pH, and time
Solution Approach 1:
The system uses sensors to automatically detect part parameters and adjusts processing conditions without operator intervention. The control system self-regulates heat, pH, and time parameters based on detected part characteristics, eliminating manual adjustment time while maintaining versatility across different part types
Solution Approach 2:
The system incorporates sensors that continuously monitor part parameters and provide feedback to the control system. This closed-loop feedback mechanism enables automatic adjustment of processing conditions, allowing the system to adapt to various part types without requiring manual parameter changes by the operator
2Ease of operation
If the part moves freely in the tank, then the system is simple to operate, but the center of mass movement causes inefficiency and potential collisions with tank walls
Solution Approach 1:
The system uses opposing forces through multiple jets positioned around the tank to counterbalance the part's movement and keep it centered. The jets create controlled counter-forces that prevent the part from drifting to tank walls, maintaining processing efficiency without complex mechanical constraints
Solution Approach 2:
The system employs hydraulic or pneumatic jets to control part position and movement. By adjusting jet pressure and direction, the system maintains optimal part positioning and prevents collisions with tank walls, improving support removal efficiency while keeping the system simple to operate
3Ease of operation
If the part moves freely in the tank, then the system is simple to operate, but the part may collide with tank walls or machine components causing fracture
Solution Approach 1:
The system uses opposing forces through multiple jets positioned around the tank to counterbalance the part's movement and keep it centered. The jets create controlled counter-forces that prevent the part from drifting to tank walls, maintaining processing efficiency without complex mechanical constraints
Solution Approach 2:
The system proactively controls part movement using sensors and adjustable jets to prevent collisions before they occur. By continuously monitoring part position and adjusting jet forces, the system cushions the part against potential impacts with tank walls, ensuring part integrity throughout the processing cycle
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
Maximizes energy efficiency and minimizes part damage by ensuring uniform exposure to support removal agents, allowing for a wide variety of part types without manual intervention.
Implementation Method 1
A support removal machine that responds automatically to changing conditions within a tank and structural changes in the part while maintaining the part in optimal location within the tank for support removal. The continuous regulation of part motion and tank parameters, through a novel combination of liquid flow, heat, ultrasonic radiation, and measurement capabilities, maximizes the use of energy and minimizes damage to the part.
Implementation Method 2
Additional known methods of support removal for three dimensional objects include raising and lowering temperature in a support removal tank to melt the support material, where the support material has a lower melting point than the part.
Implementation Method 3
Various systems exist for removing support material from a 3D printed part. These systems often relate to methods for agitating a 3D printed part in a liquid media designed to erode support material surrounding the part.
Data Source
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Figure 3A~4B
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AI summary
An apparatus and method for removing support material from a part formed by three- dimensional (3D) printing. The support removal machine contains a tank for submersion of a 3D printed part into a liquid mass. The liquid mass circulates in the tank in a controlled manner such that submerged parts remain centrally suspended in the tank, regardless of the material, density and geometry comprising the part. The part circulates and rotates in conjunction with the rotational flow of the liquid mass for uniform exposure to means of support removal. During rotation, the part may be subjected to multiple means of agitation that include heat, chemical and ultrasonic, in order to optimize energy use and maximize efficiency of the removal of support material.