Flexible Grid Support Structure for 3D Printed Objects

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Solution Overview

Problem

Current 3D printing processes require manual handling and transfer of individual printed parts for post-processing, which is inefficient and can cause objects to fuse together, especially when multiple parts are involved.

Innovation Solution

A support structure is generated and printed alongside objects, allowing for efficient handling and post-processing by reconfiguring from a flat to a cylindrical configuration, enabling automated processing without the need for individual part handling, using a grid structure with flexible and connector elements to maintain object separation and facilitate easy transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual handling and transfer of individual printed parts is used for post-processing, then each part can be processed separately, but the process becomes inefficient and parts may fuse together

Engineering Contradiction:

Improvepost-processing efficiencyVSAvoidpart separation

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Multiple individual parts are merged onto a single support structure base portion, allowing them to be handled and processed simultaneously as one unit. The support structure integrates multiple parts with the base portion, enabling collective post-processing operations like bead blasting and chemical polishing without requiring separate handling of each part.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The support structure acts as an intermediary between the printed parts and the handling system. Instead of directly handling individual parts, the support structure provides a unified interface for grasping and transferring multiple parts together, preventing direct contact between parts that could cause fusion while maintaining secure handling.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If multiple parts are handled individually, then each part receives adequate processing, but the time and complexity increase significantly

Engineering Contradiction:

Improvepost-processing qualityVSAvoidpost-processing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Multiple parts are combined on a single support structure, allowing simultaneous post-processing operations. The base portion provides a common platform that enables all attached parts to undergo processing like bead blasting and chemical polishing at the same time, dramatically reducing total processing time while maintaining consistent quality across all parts.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If parts are processed separately, then processing quality is maintained, but automation becomes difficult to implement

Engineering Contradiction:

Improvepost-processing qualityVSAvoidautomated processing capability

Core Design Contradiction:

Manufacturing precisionVSExtent of automation

Solution Approach 1:

The support structure serves as an intermediary that enables automation by providing a single, unified grasping point for robotic or automated handling systems. Instead of requiring complex multi-point manipulation of individual parts, the automated system can grasp the base portion and manipulate the entire assembly, making automation feasible while maintaining processing quality through consistent handling.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Strength

If a rigid support structure is used, then structural strength is maintained, but flexibility for reconfiguration is lost

Engineering Contradiction:

Improvesupport structure strengthVSAvoidconfiguration flexibility

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The support structure employs local quality variation by making the base portion flexible while keeping the connection points and part-holding features rigid. This allows the base to bend and reconfigure into different shapes (flat, cylindrical, etc.) while maintaining sufficient structural strength at critical locations to support parts and withstand processing forces.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The support structure transitions from a static rigid form to a dynamic reconfigurable form. The flexible base portion enables the structure to adapt its configuration based on processing requirements, allowing reconfiguration between flat and cylindrical shapes while maintaining adequate strength through the printed material properties and geometric design.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20230182400A1Support structure generation for 3D printed objects

Publication Date: 2023.06.15 PERIDOT PRINT LLC

AI summary

Support structure generation is described in which object model data relating to a plurality of three-dimensional objects to be printed by a three-dimensional printer may be obtained. A support structure such as a grid structure for supporting the objects during post-processing of the generated objects is generated. The grid support structure comprises a base portion printable in a substantially flat orientation and a connection element for releasably connecting each object to the base portion. The base portion comprises a flexible portion to enable the base portion that is printable in a substantially flat orientation to be formed into another configuration after printing without breakage of the base portion. Each object may be positioned on the base portion via a releasable connection element. Modified model data representing both the plurality of objects and the grid support structure, for printing by the additive manufacturing system, may then be obtained.