3D Printed Support Markers for Accurate Automated Removal
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Solution Overview
Problem
Current 3D printing technologies face limitations in automation, leading to high costs and inefficiencies due to manual pre- and post-processing steps, particularly in accurately removing support structures from 3D printed components, which results in inconsistent and time-consuming post-processing processes.
Innovation Solution
A system that prints markers on 3D printed components or support structures during the printing process, allowing for autonomous identification and cutting path determination using computer vision and machine learning to accurately separate the support structures from the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated removal of support structures is performed using pre-programmed path trajectories, then automation level increases, but cutting accuracy decreases due to physical deformations causing inconsistent cuts
Solution Approach 1:
The marker is printed on the support structure during the 3D printing process itself, before post-processing occurs. This preliminary placement of the marker enables the cutting system to later identify and compensate for any physical deformations that occurred during printing, allowing automated cutting to remain accurate despite variations in the support structure's final position or shape.
Solution Approach 2:
The patent replaces reliance on purely mechanical pre-programmed cutting paths with an optical/image-based marker detection system. The marker provides visual feedback that allows the cutting system to adapt to actual physical deformations, substituting rigid mechanical trajectory following with a more flexible vision-guided approach that can compensate for variations.
2Manufacturing precision
If manual methods are used to separate support structures from components, then cutting accuracy can be maintained, but productivity decreases due to time-consuming manual processes
Solution Approach 1:
The support structure carries its own identification marker that enables the automated cutting system to locate and process it without human intervention. The marker acts as a self-identifying feature that allows the system to service the support structure removal automatically, eliminating the need for manual positioning or guidance while maintaining accuracy.
Solution Approach 2:
The marker serves as an intermediary between the support structure and the automated cutting system. It provides a reliable interface that allows the automated system to 'see' and 'understand' the support structure's location and boundaries, enabling accurate automated cutting without requiring manual intervention or complex sensor systems.
3Ease of operation
If fluids are used to dissolve support structures away from components, then manual labor is reduced, but manufacturing precision deteriorates due to inability to control dissolution location accurately
Solution Approach 1:
The marker acts as an intermediary that guides the cutting process, providing precise location information to the automated cutting system. This allows the system to know exactly where to cut through the support structure and component interface, achieving accurate separation that fluid dissolution cannot provide while still maintaining ease of automated operation.
Data Source
AI summary
A system and method are described for post-processing a 3D printed component. For example, support structures for the 3D printed component may be removed during post-processing. In the system and method, a marker is placed on the 3D printed component or on a support structure attached to the 3D printed component. The marker may be printed while the 3D printed component and the support structures are printed by a 3D printer. After printing, the marker may then be sensed to determine one or more cutting paths between the 3D printed component and the support structures. The 3D printed component may then be autonomously separated from the support structures by cutting through the cutting path.