Additive Manufacturing Demolding via Shockwave Separation

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Solution Overview

Problem

Additive manufacturing often results in components being bonded to build platforms, making separation challenging without causing deformation or damage, especially for complex geometries where conventional cutting or machining is inefficient.

Innovation Solution

The method involves generating shockwaves in the additively manufactured component or substrate to create tensile stress at the interface, allowing for precise separation without damaging the component, using techniques like laser-generated or explosion-generated shockwaves to apply controlled stress for demolding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional cutting or machining is used to separate the additively manufactured component from the build platform, then separation can be achieved, but the component may be damaged and the build platform cannot be re-used

Engineering Contradiction:

Improveseparation processVSAvoidcomponent damage

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent replaces conventional mechanical cutting or machining methods with an electromagnetic field-based approach. A coil generates a magnetic field that induces eddy currents in the conductive build platform, creating localized heating that weakens the bond between the component and platform, enabling separation without mechanical contact and thus preventing component damage

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state of the build platform by using electromagnetic induction to generate localized heat at the interface between the component and platform. This thermal parameter change softens or weakens the bonding material, allowing for damage-free separation of the component from the platform

Inventive Principle:

Principle #35Parameter changes

2Productivity

If prying, chiseling, or cutting is used to separate the component from the build platform, then separation can be achieved, but undesired forces can deform or damage the object

Engineering Contradiction:

Improveseparation efficiencyVSAvoidcomponent integrity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent replaces mechanical prying, chiseling, or cutting operations with an electromagnetic field-based separation method. The coil generates a magnetic field that induces eddy currents in the build platform, creating localized thermal effects that weaken the bond without applying mechanical forces to the component, thus maintaining component integrity while achieving efficient separation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If cutting or machining the build platform is used to separate the component, then separation can be achieved, but the build platform is damaged and cannot be re-used

Engineering Contradiction:

Improveseparation processVSAvoidbuild platform re-usability

Core Design Contradiction:

Ease of manufactureVSDuration of action of stationary object

Solution Approach 1:

The patent replaces mechanical cutting or machining of the build platform with an electromagnetic induction-based method. The coil generates a magnetic field that induces eddy currents, creating localized heating at the component-platform interface that weakens the bond without removing or damaging the platform material, thereby preserving the platform for reuse

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses electromagnetic induction to create localized thermal parameter changes at the bonding interface. The induced eddy currents generate heat that softens or weakens the bonding material temporarily, allowing for easy separation without permanently damaging the build platform, thus maintaining its re-usability

Inventive Principle:

Principle #35Parameter changes

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 accurate and damage-free separation of additively manufactured components from build platforms, reducing the risk of deformation and preserving the integrity of the components, especially for complex geometries where conventional methods are ineffective.

Implementation Method 1

generating a shockwave in at least one of an additively manufactured component or a substrate upon which the additively manufactured component is built

Methodology Applied

Scientific EffectShockwave: Shock Wave

Implementation Method 2

using techniques like laser-generated or explosion-generated shockwaves to apply controlled stress for demolding

Methodology Applied

Scientific EffectLaser-generated shockwave: Laser Ablation

Implementation Method 3

using techniques like laser-generated or explosion-generated shockwaves to apply controlled stress for demolding

Methodology Applied

Scientific EffectExplosion-generated shockwave: Explosion

Implementation Method 4

applying a tensile stress at an interface between the additively manufactured component and the substrate to separate at least a portion of the additively manufactured component from the substrate along the interface

Methodology Applied

Scientific EffectTensile stress: Tension

Data Source

PatentUS20240286197A1Systems and methods for demolding additively manufactured components

Publication Date: 2024.08.29 THE BOEING CO

AI summary

A system and method for demolding an additively manufactured component includes generating a shockwave in at least one of the additively manufactured component and the substrate upon which the additively manufactured component is built and applying a tensile stress at an interface between the additively manufactured component and the substrate to separate at least a portion of the additively manufactured component from the substrate along the interface in response to the tensile stress.