Additive Manufacturing Support Structures with Detachable Coupling
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Solution Overview
Problem
Additive manufacturing techniques often result in thermal and mechanical stresses that can deform objects or cause build failures due to the heating and cooling of materials during the manufacturing process, and existing support structures complicate the removal process, increasing time and cost.
Innovation Solution
The use of detachable coupling mechanisms and torque application portions on supports and base plates allows for easier detachment and removal of supports from both the object and the base plate, utilizing detachable coupling mechanisms and torque application portions to facilitate rotational force application, reducing the complexity of support removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional support structures are used during additive manufacturing, then the object is supported and prevented from deformation during manufacturing, but the support removal process becomes complex and time-consuming
Solution Approach 1:
The support structure is divided into multiple segments that can be independently removed. Each support includes a support body portion and a support base portion that can be separated from each other, allowing for easier and more efficient removal compared to traditional monolithic support structures
Solution Approach 2:
The support base portion is extracted as a separate removable component from the support structure. This extracted portion can be easily detached from the build plate, leaving the support body portion that remains attached to the manufactured object, thereby simplifying the overall removal process
2Reliability
If traditional support structures are used during additive manufacturing, then the object is supported and prevented from deformation during manufacturing, but the device complexity increases due to additional post-processing steps
Solution Approach 1:
The support structure is divided into multiple segments that can be independently removed. Each support includes a support body portion and a support base portion that can be separated from each other, allowing for easier and more efficient removal compared to traditional monolithic support structures
Solution Approach 2:
The support base portion is extracted as a separate removable component from the support structure. This extracted portion can be easily detached from the build plate, leaving the support body portion that remains attached to the manufactured object, thereby simplifying the overall removal process
3Manufacturing precision
If supports are used to prevent thermal and mechanical stresses from deforming the object, then manufacturing accuracy is maintained, but the manufacturing cost increases due to extra post-processing
Solution Approach 1:
The support structure is divided into multiple segments that can be independently removed. Each support includes a support body portion and a support base portion that can be separated from each other, allowing for easier and more efficient removal compared to traditional monolithic support structures
Solution Approach 2:
The support base portion is extracted as a separate removable component from the support structure. This extracted portion can be easily detached from the build plate, leaving the support body portion that remains attached to the manufactured object, thereby simplifying the overall removal process
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 quicker and more efficient removal of supports, reducing manufacturing time and costs while maintaining the accuracy of the final object by minimizing deformation and simplifying the post-processing steps.
Implementation Method 1
a torque application portion configured to allow a rotational force to be applied to break at least a portion of the support from at least one of the object, the other object, and the base plate
Implementation Method 2
a first portion of a coupling element, the coupling element comprising the first portion of the coupling element and a second portion of the coupling element, wherein the first portion of the coupling element is configured to detachably couple to the second portion of the coupling element
Implementation Method 3
These stresses and strains may, for example, be caused by the heating and cooling of the raw building materials, which leads to expansion and shrinkage of the material during manufacturing
Implementation Method 4
Additive manufacturing techniques using an energy source to process raw building materials tend to create thermal and mechanical stresses and strains during the manufacturing process
Data Source
AI summary
Embodiments of the present invention may relate to supports and methods of manufacturing such supports that reduce the complexity of removing the supports from the object and/or a base plate. In some embodiments, the present invention relates to base plates and methods of manufacturing base plates that reduce the complexity of removing supports from the base plate.