Laser Severing Device for Metal 3D Printed Objects
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Solution Overview
Problem
Existing methods for severing metal-containing 3D objects from a base plate in 3D printing apparatuses are inefficient, requiring significant setup time and manual intervention, leading to prolonged downtime and potential deformation of heavy workpieces.
Innovation Solution
A severing device with a first machining unit, equipped with a machining tool like a diamond wire saw, and a second machining unit for cleaning, both connected to the 3D printing apparatus and driven by a control unit, allowing for automated and precise severing and surface cleaning, enabling rapid reuse of the base plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional metal saws or wire erosion processes are used for severing, then the workpiece can be separated from the base plate, but the base plate becomes unavailable for extended periods and requires additional machining time
Solution Approach 1:
The patent replaces conventional mechanical severing methods (metal saws, wire erosion) with a laser-based severing system. The laser beam mechanically separates the workpiece from the base plate through localized melting and vaporization, eliminating the need for extensive post-machining and reducing base plate downtime.
Solution Approach 2:
The invention extracts the severing function from the base plate processing sequence by implementing a dedicated laser severing unit that operates independently. This allows the workpiece to be separated without requiring the entire base plate to be removed or repositioned, enabling faster turnaround.
2Stability of the object's composition
If robust base plates are used for heavy workpieces, then deformation during production is avoided, but severing the workpiece from the base plate becomes more difficult
Solution Approach 1:
The laser-based severing system overcomes the difficulty of cutting through robust base plates by using high-energy density laser beams that can penetrate and separate thick, heavy-duty base plates without requiring excessive mechanical force or complex sawing operations.
3Reliability
If supporting structures are provided at transition points, then the workpiece can be properly supported during printing, but additional post-machining steps are required to remove them
Solution Approach 1:
The laser severing system automatically removes supporting structures during the severing process itself, combining the separation function with the cleanup function. This eliminates the need for separate post-machining steps to remove support structures, reducing overall process complexity.
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 solution enables quick and precise severing of metal-containing 3D objects from the base plate, reducing setup times and ensuring compliance with stricter tolerance limits, thus enhancing product quality and minimizing downtime for further manufacturing.
Implementation Method 1
selective laser melting (SLM)... locally melted with a laser beam at predetermined points, wherein the material then rapidly solidifies
Implementation Method 2
mechanically severing metal-containing 3D objects from a base plate
Implementation Method 3
cleaning at least part of the surface of the base plate
Data Source
AI summary
A severing device for mechanically severing metal-containing 3D objects from a base plate of a 3D printing apparatus is provided. The severing device has at least one first machining unit firmly connectable to the 3D printing apparatus with at least one machining tool which has a working zone which encompasses at least part of an area of the base plate.