Locking Cavity Plug for Clean Additive Part Removal

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Solution Overview

Problem

Conventional additive manufacturing systems face issues with internal contamination of components due to debris entering cavities during removal from build plates, leading to performance impediments and costly post-processing.

Innovation Solution

A cavity plug with an outer shell and locking mechanism, featuring pivotable locking arms, is used to seal and secure the cavity, allowing components to be removed without contaminating internal cavities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If components are removed from build plate using conventional methods (saw or wire EDM), then component removal is achieved, but swarf and debris enter into the cavities causing internal contamination

Engineering Contradiction:

Improvecomponent removalVSAvoidinternal contamination

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

A cavity plug is introduced as an intermediary component that temporarily seals the cavity opening during the component removal process. The plug acts as a barrier between the external debris environment and the internal cavity, preventing contamination while allowing the component to be removed using conventional methods.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The cavity plug is installed in advance before the component removal operation. By sealing the cavity opening prior to removal, the system prevents potential contamination from occurring in the first place, eliminating the need for subsequent cleaning operations.

Inventive Principle:

Principle #10Preliminary action

2Object-affected harmful factors

If cavity plugs are used to seal cavities during component removal, then internal contamination is prevented, but device complexity increases due to additional locking mechanisms

Engineering Contradiction:

Improveinternal contaminationVSAvoidlocking mechanism

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The locking mechanism is segmented into multiple independent locking arms that can engage with the cavity wall at different locations. This segmentation allows the system to achieve reliable sealing through distributed engagement points, reducing the complexity of any single locking element while maintaining overall effectiveness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The locking arms are designed to be movable and adaptable, allowing them to adjust their position and orientation to match the cavity geometry. This dynamic capability enables the locking mechanism to accommodate variations in cavity shape and size without requiring a completely new design for each case.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentEP4534222B1Cavity plug for additive part removal from build plate

Publication Date: 2026.03.18 GENERAL ELECTRIC TECH GMBH

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AI summary

The present application provides a cavity plug (370) for a cavity (360) extending through a first wall (320) of a component (110) manufactured in an additive manufacturing system (100). The cavity plug (370) may include an outer shell (380), a first seal (410) sized to seal about the cavity (360) extending through the first wall (320) of the component (110), and a locking mechanism (450) positioned within the outer shell (380). The locking mechanism (450) includes a locking arm (460) to engage the first wall (320) and seal the cavity plug (370) in place.