3D Printing Platform With Openings For Damage-Free Part Removal

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Solution Overview

Problem

Conventional stereolithography (SLA) methods require labor-intensive and time-consuming support structures for removing three-dimensional articles, which can damage the parts and prolong fabrication time.

Innovation Solution

A platform with a plurality of openings is used, allowing for the formation of three-dimensional articles without support structures, enabling their quick and damage-free removal using a punch or tool with projections that engage the platform openings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If support structures with sierras are used in conventional SLA, then the object can be removed from the apparatus, but the fabrication time increases and the removal process remains labor intensive

Engineering Contradiction:

Improveobject removalVSAvoidfabrication time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The invention extracts and eliminates the support structure component entirely by replacing it with a platform featuring openings that allow direct object removal. The platform with openings enables the object to be accessed and removed without requiring auxiliary support structures, thereby reducing fabrication time while maintaining ease of removal.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of using solid support structures that require cutting and removal, the invention inverts the approach by using a platform with openings (negative space) that allows direct access to and removal of the object. This inversion eliminates the need for sierras and support structures, reducing both fabrication time and labor intensity.

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If support structures are used in conventional SLA, then the object can be held during fabrication, but the supports require labor-intensive removal that may damage the part

Engineering Contradiction:

Improveobject integrityVSAvoidremoval process

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The invention removes the support structure element entirely and replaces it with a platform containing openings. These openings allow the object to be accessed and removed directly from below, eliminating the need for labor-intensive support removal processes that risk damaging the part while maintaining proper object support during fabrication.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The platform with openings serves as an intermediary structure that provides support during fabrication while simultaneously enabling easy object removal. The openings act as a mediator that allows tool access to the object without requiring removal of support structures, thus protecting object integrity while simplifying the removal process.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If support structures with sierras are used, then contact points are minimized, but the fabrication time is lengthened and removal remains labor intensive

Engineering Contradiction:

Improvesupport structure designVSAvoidmanufacturing speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The invention extracts the support structure concept and replaces it with a platform containing openings. This eliminates the need to design and fabricate sierras and support structures entirely, thereby increasing manufacturing speed while maintaining ease of object removal and platform design simplicity.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of designing support structures with minimized contact points using sierras, the invention inverts the approach by using a platform with openings that provides support through the openings themselves. This inversion eliminates the need for complex support structure design while increasing manufacturing speed and simplifying the removal process.

Inventive Principle:

Principle #13The other way round (Inversion)

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 method reduces manufacturing time and costs by eliminating the need for support structures, allowing for faster and more efficient removal of finished parts without breakage.

Implementation Method 1

Stereolithography (SLA) prototypes are constructed from a liquid photopolymer that is selectively cured using an ultraviolet laser

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentUS7481647B2Systems and methods for fabricating 3-D objects

Publication Date: 2009.01.27 ALIGN TECHNOLOGY INC

AI summary

Systems and methods are disclosed for a platform to form a three-dimensional article from successively selectively solidified layers of a liquid medium which is solidifiable by application thereto of a prescribed energy. The platform can be coated or uncoated. The platform can have an array of openings therethrough. Upon completion, the article can be removed from the platform using a punch having a plurality of projections adapted to engage openings in the platform. Alternatively, a tool can be used to push articles from the platform.