Datum Structure for AM Object Removal from Build Platform
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Solution Overview
Problem
Additive manufacturing (AM) processes face challenges in efficiently removing objects from non-horizontal and non-planar build platforms, leading to increased costs and time due to the need for extensive machining and waste generation.
Innovation Solution
A datum structure with a vertical reference plane is positioned relative to the build platform, which is coplanar with the removal plane of the AM structure, guiding a cutting element to remove the object accurately and efficiently, reducing the need for precise platform alignment and planarity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the build platform is made non-horizontal and non-planar to accommodate complex geometries, then manufacturing flexibility is improved, but object removal precision deteriorates
Solution Approach 1:
A datum structure with a vertical reference plane is introduced as an intermediary element between the non-horizontal build platform and the cutting element. This datum structure provides a stable reference that mediates the interaction, allowing the cutting element to accurately locate and cut through objects regardless of the platform's orientation or planarity, thus resolving the precision problem while maintaining manufacturing flexibility
Solution Approach 2:
The solution introduces a vertical reference plane dimension that is independent of the build platform's horizontal orientation. By establishing a vertical reference system rather than relying on the platform's horizontal surface, the cutting process gains a new dimensional reference that remains accurate even when the platform is non-horizontal or non-planar
2Reliability
If extensive machining is performed to remove objects from the build platform, then complete object removal is achieved, but manufacturing time and cost increase
Solution Approach 1:
The datum structure is built during the additive manufacturing process itself, before the object removal stage. This preliminary action establishes the reference system in advance, enabling precise cutting to occur immediately after manufacturing without requiring time-consuming trial-and-error machining operations to achieve complete object removal
3Manufacturing precision
If the build platform requires high precision alignment and planarity, then object removal accuracy is improved, but device complexity and setup time increase
Solution Approach 1:
The reference function is extracted from the build platform itself and transferred to a separate datum structure. Instead of requiring the platform to provide both support and precision reference functions, the reference function is taken out and embodied in the dedicated datum structure with its vertical reference plane, simplifying platform requirements while maintaining high accuracy
Data Source
AI summary
An additively manufactured (AM) structure includes a removal plane extending therein defining an object thereabove. The AM structure also includes at least one datum structure coupled relative to the AM structure. Each datum structure includes a vertical reference plane for guiding a cutting element to remove the object from a remaining portion of the AM structure through the removal plane. The vertical reference plane is horizontally coplanar with the removal plane of the AM structure. The datum structures allow for accurate object cuts regardless of whether an AM build platform is horizontal or non-planar.