Additive Manufacturing Support Removal via Chemical Etching
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for removing support structures in additive manufacturing, such as selective laser melting, are time-consuming and costly due to manual processing, and struggle with accessing difficult-to-reach areas like cooling channels.
Innovation Solution
A method for tool-free, automated removal of support structures using chemical or electrochemical etching at predetermined separation points, where the support structures are designed to be quickly dissolved, allowing for efficient separation without mechanical tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual processing methods (hammer, chisel, pliers) are used to remove support structures, then the support structures can be removed from components, but the process becomes very time-consuming and costly
Solution Approach 1:
The patent replaces manual mechanical removal methods (hammer, chisel, pliers) with chemical etching processes. The support structures are designed with specific chemical compositions or surface properties that make them susceptible to chemical dissolution, thereby substituting mechanical force with chemical reactions for support structure removal.
Solution Approach 2:
The patent modifies the chemical composition or surface parameters of the support structures to create differential etchability. By changing the material parameters (adding etch-sensitive materials, creating porous structures, or applying coatings), the support structures become selectively removable through chemical etching while the component remains intact.
2Ease of operation
If manual processing tools are used to remove support structures, then support structures can be accessed and removed, but difficult-to-access areas (such as cooling channels) cannot be removed or require considerable effort
Solution Approach 1:
The patent replaces mechanical tools that require physical access with chemical etching agents that can penetrate into internal cavities and cooling channels. The chemical etchant flows through the component's internal passages and dissolves support structures in locations that would be inaccessible to manual tools.
Solution Approach 2:
The patent uses chemical etchants as intermediaries to reach and remove support structures in difficult-to-access areas. The etching solution acts as a mediator that can navigate through complex internal geometries and chemically interact with support structures without requiring direct mechanical access.
3Ease of manufacture
If support structures are designed with separation points for easier removal, then mechanical separation becomes easier, but the removal process still requires manual intervention and tools
Solution Approach 1:
The patent replaces manual mechanical separation at predefined separation points with automated chemical etching processes. The separation points are designed with enhanced chemical etchability, allowing automated immersion in etching solutions to cleanly separate support structures without manual intervention.
Solution Approach 2:
The patent designs support structures that self-dissolve through chemical etching at predetermined separation points. The structures are engineered to be inherently susceptible to chemical dissolution, eliminating the need for external mechanical tools or manual operations to achieve separation.
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
Enables rapid, automated, and cost-effective removal of support structures, including internal ones, reducing processing time and surface roughness, and facilitating series production without mechanical damage to components.
Implementation Method 1
the support structures are separated from the components by chemically or electrochemically dissolving the structure at the intended separation points
Implementation Method 2
the support structures are separated from the components by chemically or electrochemically dissolving the structure at the intended separation points
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a method for the tool-free removal of support structures in the additive manufacturing of one or more components. The components (1) are built in layers together with support structures (2) for supporting regions of the components (1), and the support structures (2) are removed from the components (1) after the complete construction of the components. The support structures (2) are constructed in such a way that they have target separation points (4) at a transition to the components (1), which have a structure that breaks down more easily in relation to component parts and preferably also other parts of the support structures (2) due to a chemical or electrochemical reaction. The support structures (2) are then separated from the components (1) via the chemical or electrochemical break down of the structure at the target separation points (4). With this tool-free removal of the support structures (2), the components (1) can be both arranged in parallel and also completely automatically processed.