Atomized Fluid Spray Apparatus for AM Support Removal
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Solution Overview
Problem
Additive manufacturing techniques produce parts with complex geometries that require significant effort to remove unwanted support material and smooth rough surfaces, leading to potential stress concentrations and premature failure due to manual labor inefficiencies and inconsistencies.
Innovation Solution
An apparatus and method using atomized or semi-atomized fluid, chemical dissolution, and pressurized fluid to automatically remove support material and smooth surfaces of additively manufactured parts, featuring a chamber with nozzles and a tank for recycling the fluid, and a diverter to prevent foaming, allowing for adjustable parameters to tailor the process to specific parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual labor is used to remove support material and finish surfaces, then flexibility and adaptability are maintained, but productivity is reduced and consistency is poor
Solution Approach 1:
The patent replaces manual mechanical operations with an automated fluid-based system. A spray apparatus delivers atomized or semi-atomized fluid to the additively manufactured part, automatically removing support material and smoothing surfaces without direct human intervention. This substitution dramatically increases productivity while maintaining process control through automated fluid delivery parameters.
Solution Approach 2:
The invention utilizes pressurized fluid delivery systems to achieve automated support removal. The spray apparatus employs pneumatic or hydraulic mechanisms to atomize and direct fluid onto the part surface, enabling consistent, high-speed processing. This fluid-based approach replaces manual mechanical tools while maintaining adaptability through adjustable pressure and flow rates.
2Extent of automation
If chemical bath machines are used for support removal, then automation is increased, but adaptability is reduced and operational complexity increases
Solution Approach 1:
The patent implements a dynamic spray system where fluid delivery parameters (pressure, flow rate, atomization level, spray angle) can be adjusted in real-time to match specific part geometries and support material types. This dynamic adjustability provides both automation and versatility, allowing the same apparatus to handle diverse parts without reconfiguration, unlike fixed chemical bath systems.
Solution Approach 2:
The invention changes physical parameters of the fluid delivery system (pressure, temperature, atomization degree) to optimize support removal for different part configurations. These parameter adjustments enable the automated system to adapt to various part types and materials, overcoming the rigidity of chemical bath machines while maintaining high automation levels.
3Manufacturing precision
If manual surface finishing is performed, then surface quality can be adjusted, but time consumption increases and surface consistency deteriorates
Solution Approach 1:
The patent replaces manual surface finishing operations with an automated spray system that delivers atomized fluid to smooth part surfaces. This substitution eliminates the time-consuming nature of manual finishing while maintaining consistent surface quality through controlled fluid delivery parameters. The process simultaneously removes support material and finishes surfaces in a single automated operation.
Solution Approach 2:
The invention enables continuous surface finishing through automated spray delivery that can operate without interruption. The fluid-based system maintains constant contact with the part surface, providing continuous smoothing action rather than the intermittent nature of manual finishing. This continuity dramatically reduces processing time while ensuring uniform surface quality across the entire part.
4Ease of operation
If support material is extensively removed manually, then complex geometries can be accessed, but material loss increases and labor effort increases
Solution Approach 1:
The patent uses directed fluid spray to access and remove support material from complex internal geometries that would be difficult to reach with manual tools. The atomized or semi-atomized fluid can penetrate intricate passages and cavities, effectively removing support material without requiring excessive material removal. This fluid-based approach minimizes material loss while maintaining ease of operation for complex parts.
Solution Approach 2:
The invention segments the support removal process into controlled fluid applications that target specific areas. The spray system can be directed to specific zones requiring support removal, rather than requiring blanket material removal. This segmented approach allows precise access to complex geometries while minimizing unnecessary material loss.
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
Automatically removes support material and smooths surfaces without damaging the parts, reducing manual labor bottlenecks and inconsistencies, enhancing production efficiency and part quality by ensuring consistent surface finishing across multiple parts.
Implementation Method 1
The nozzles may be configured to spray a fluid at the AM part, and the spray may be an atomized or semi-atomized spray of the fluid
Implementation Method 2
embodiments of the present invention, which use atomized and semi-atomized fluid, chemical dissolution, and pressurized fluid
Implementation Method 3
one or more nozzles within the chamber, and configured for spraying a fluid at said AM part
Data Source
AI summary
An apparatus and method for removing support material from and/or smoothing surfaces of an additively manufactured part (the “AM part”) is disclosed. The apparatus may include a chamber, a support surface within the chamber, one or more nozzles within the chamber, a tank positioned below the nozzles, and a diverter positioned between the nozzles and the tank. The support surface may be configured to support the AM part and may have one or more openings configured to allow the fluid to pass through the opening(s). The nozzles may be configured to spray a fluid at the AM part, and the spray may be an atomized or semiatomized spray of the fluid. The diverter comprises an umbrella or a diverter shield and diverts sprayed fluid from directly impacting the fluid being collected in the tank, whereby foaming of the fluid in the tank is reduced.