Collar-Based Billet Substrate Release for Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing processes face challenges in post-processing, particularly in removing articles from build plates without damaging thin or fragile geometries, often requiring destructive techniques like wire EDM.
Innovation Solution
A method involving a billet substrate secured to a build plate with a collar that allows for the formation of articles like heat exchanger fins, enabling their removal as an integral unit without destructive processes, using a depression in the build plate and fasteners like screws or twist locks, and optionally thermal paste for attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wire EDM is used to remove the article from the build plate, then the article can be removed, but thin or fragile geometries may be damaged
Solution Approach 1:
The build plate is segmented into a reusable base plate and a removable collar assembly. The collar can be detached to release the article from the build plate, allowing non-destructive removal while preserving the build plate for reuse.
Solution Approach 2:
The collar acts as an intermediary component between the article and the build plate. It provides a release mechanism that allows the article to be removed without direct contact between the article and the build plate, preventing damage to fragile geometries.
2Strength
If a base is formed on the build plate during additive manufacturing, then the article can be supported during building, but the build plate cannot be reused after removal
Solution Approach 1:
The support structure is segmented into a permanent build plate and a removable collar. The collar is removed after the article is built, allowing the build plate to be reused for subsequent manufacturing cycles without degradation.
Solution Approach 2:
The collar is designed as a disposable or reusable accessory that is removed after serving its support function. This allows the expensive build plate to be recovered and reused, improving overall productivity.
3Device complexity
If traditional additive manufacturing is used without a collar, then the process is simple, but destructive post-processing is required and thin geometries are damaged
Solution Approach 1:
The collar is introduced as a simple intermediary component that interfaces with the build plate and article. It provides a release mechanism that enables non-destructive removal without significantly complicating the additive manufacturing process itself.
Solution Approach 2:
The collar is designed to be easily attached and removed by the operator without requiring complex mechanisms or specialized equipment. The release mechanism allows the article to be self-releasing when the collar is removed, simplifying the post-processing step.
Data Source
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AI summary
A method of forming an article such as fins for a heat exchanger. The method includes: providing a billet substrate (202); securing the billet substrate to a build plate (200) of an advanced manufacturing device with a collar (204), wherein the collar is at least partially disposed in the build plate when the billet substrate is secured to the build plate; repeatedly adding layers on top of the billet substate to form the article, e.g. fins for the heat exchanger; releasing the collar from the build plate; and removing the billet substrate and the article e.g. fins formed thereon from the build plate.