Floating Structures for Powder Removal in Additive Manufacturing
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Solution Overview
Problem
In additive manufacturing, particularly with powder bed modalities, removing excess powder from parts with complex internal geometries and cavities is challenging due to the parts being in a 'green' state, which are less robust and prone to damage from traditional vibration methods.
Innovation Solution
The implementation of a floating structure within the part, formed concurrently via additive manufacturing, which is mechanically decoupled and vibrates to push out the powder, reducing the need for external forces and minimizing part damage during the powder removal process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional vibration methods are used to remove powder from green parts, then powder removal efficiency is improved, but part damage risk increases
Solution Approach 1:
The invention divides the powder removal function into two parts: the green part and separate floating structures. The floating structures are mechanically decoupled from the part and perform the vibration function independently, preventing damage to the green part while maintaining powder removal efficiency
Solution Approach 2:
The floating structures act as intermediary elements between the vibration source and the powder. These structures vibrate to remove powder but are not mechanically coupled to the green part, serving as a mediator that eliminates direct mechanical stress on the part
2Productivity
If high external forces are applied to remove powder from complex geometries, then powder removal completeness is improved, but part structural integrity deteriorates
Solution Approach 1:
The floating structures are self-contained units that perform powder removal within complex geometries without requiring external forces applied to the green part. Each floating structure independently vibrates to remove powder from its local environment, enabling complete powder removal from complex internal geometries without compromising part integrity
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 powder removal efficiency, reduces the risk of part damage, and allows for effective removal from complex geometries without requiring high external forces or vibrations, especially beneficial for parts in a green state.
Implementation Method 1
vibrating the part and the powder removal feature
Data Source
AI summary
An article of manufacture includes a part structure formed via a first additive manufacturing process and a floating structure within the part structure which is mechanically decoupled from the part structure. The floating structure is formed concurrently with the part structure via the first additive manufacturing process.