Connector Grids for Batch Additive Manufacturing and Post-Processing
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Solution Overview
Problem
Existing additive manufacturing processes face challenges in efficiently producing large volumes of functional polymer parts, particularly in streamlining the production process to increase efficiency and facilitate high-volume production.
Innovation Solution
The use of base connector grids that connect additively manufactured parts during and after fabrication, allowing for batch processing and simplified post-processing through methods such as transferring to a filtration basket and separating parts from the grid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional additive manufacturing processes are used to produce polymer parts, then parts can be fabricated with precision and functional properties, but production efficiency is low and volume production is difficult to achieve
Solution Approach 1:
Multiple individual parts are merged into a single integrated connector grid structure during additive manufacturing. The connector grid combines multiple part geometries and support structures into one unified buildable object, allowing simultaneous fabrication of multiple parts in a single printing operation, thereby dramatically increasing production efficiency without complicating the manufacturing process
Solution Approach 2:
The connector grid serves multiple functions: it acts as a support structure during printing, a mounting platform for multiple parts, a transfer carrier for post-processing operations, and a filtration medium for resin removal. This multi-functionality eliminates the need for separate fixtures and tools for each manufacturing stage, streamlining the entire production workflow
2Ease of manufacture
If parts are manufactured individually through additive manufacturing, then each part can be precisely fabricated, but post-processing time and complexity increase significantly
Solution Approach 1:
Multiple parts are combined with their support structures into a single connector grid assembly that is removed and post-processed as one unit. This merging allows all parts to undergo washing, curing, and other post-processing operations simultaneously, reducing total post-processing time and simplifying the workflow compared to handling each part separately
Solution Approach 2:
The connector grid acts as an intermediary carrier that holds multiple parts during post-processing. This intermediary structure enables batch processing of parts through filtration baskets and resin recovery systems, making post-processing operations more efficient and less complex than individual part handling
3Productivity
If high-volume production of polymer parts is pursued, then productivity increases, but process streamlining and efficiency optimization become more difficult
Solution Approach 1:
The build volume is segmented into multiple connector grid units, each capable of holding and manufacturing multiple parts simultaneously. This segmentation allows for modular production scaling - additional connector grids can be introduced to increase volume production capacity without proportionally increasing overall system complexity, as each unit follows the same standardized 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
Enhances efficiency by maintaining parts connected during manufacturing, simplifying post-processing, and facilitating high-volume production of polymer parts.
Implementation Method 1
a radiation source configured to emit light through the optically transparent member and solidify resin on the build surface and form the plurality of parts
Data Source
AI summary
Provided according to embodiments of the present invention are methods of additively manufacturing a plurality of parts that include fabricating a loaded base connector grid on a build platform of an additive manufacturing apparatus; removing the loaded base connector grid from the build platform and transferring the loaded base connector grid to a filtration basket set over and/or within a resin recovery bin; removing the filtration basket including the loaded base connector grid from the resin recovery bin; optionally, performing at least one post-processing method on the loaded base connector grid; removing the loaded base connector grid from the filtration basket; and separating the plurality of parts from the base connector grid. Base connector grids and related methods and apparatus are further provided.