Frangible FDM Anchor Stanchions for Damage-Free Separation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current FDM additive manufacturing processes face challenges in distinguishing between parts and stanchions, leading to difficult and costly separation processes that can damage the underlying part, and limit article orientation and formation.
Innovation Solution
A frangible connection is created between the stanchion and part layers using a shared continuous layer and tapered surfaces with gaps, allowing easy detachment without damaging the part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stanchions are formed along with the part using FDM additive manufacturing, then the part can be supported during manufacturing, but it becomes difficult to distinguish between part and stanchion, making separation difficult and time-consuming
Solution Approach 1:
The stanchion is segmented into two distinct portions: a first portion that is integrally formed with the part and provides support, and a second portion that is frangibly connected and can be easily removed. This segmentation allows the stanchion to maintain support function while enabling quick separation of the removable portion.
Solution Approach 2:
Different portions of the stanchion have different connection qualities: the first portion has a strong integral connection to the part for stable support, while the second portion has a weak frangible connection for easy removal. This local differentiation of connection strength resolves the contradiction between needing stable support and easy separation.
2Ease of manufacture
If traditional stanchion removal is performed, then the stanchion can be separated from the part, but the underlying part is often damaged
Solution Approach 1:
The frangible portion of the stanchion is designed with a localized weak connection that breaks preferentially during removal. This concentrates the mechanical stress at the frangible interface rather than propagating damage to the main part, enabling easy removal without part damage.
Solution Approach 2:
The frangible portion acts as an intermediary element between the integral support structure and the external removal force. It absorbs the mechanical stress of removal through controlled breaking, protecting the main part from damage while still allowing stanchion removal.
3Ease of manufacture
If stanchions are connected to downwardly facing planar surfaces, then the FDM process can deposit material, but article orientation and formation are limited
Solution Approach 1:
The stanchion design with both integral and frangible portions connected to different surfaces (downwardly facing and side surfaces respectively) provides multi-functional attachment capability. This allows the FDM process to maintain its layer-by-layer deposition advantage while accommodating various article orientations and formation requirements.
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
The frangible connection enables easy and damage-free separation of stanchions from parts, improving manufacturing efficiency and reducing costs.
Implementation Method 1
FDM is a process that uses a continuous filament of material to form a part. The filament of material is fed from a large spool through a heated printer head and deposited on a substrate.
Data Source
AI summary
A fused deposition modeling (FDM) additively manufactured part system includes a support substrate and a part portion arranged at the support substrate. The part portion includes a plurality of part layers having a part layer diameter. The part portion includes a downwardly facing surface and a side surface. A stanchion portion including a plurality of stanchion layers having a stanchion layer diameter supports the part portion relative to the support substrate. The stanchion portion being frangibly connected to the side surface of the part portion. A first portion of the plurality of stanchion layers solely form a segment of the stanchion portion and a second portion of the plurality of stanchion layers overlap onto a first part layer of the plurality of part layers forming the side surface.