Microwave Support Removal for 3D Printed Objects
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Solution Overview
Problem
Current methods for removing support material from three-dimensional printed objects are time-consuming and inefficient, especially as the size of printed objects increases, requiring improved techniques to enhance production speed in high-volume production.
Innovation Solution
A method and system utilizing microwave energy to heat and phase-change support material, allowing it to flow away from the object, with a susceptor and temperature sensor to control the microwave energy and prevent damage to the object, leveraging the difference in dielectric loss factors between support and build materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional methods (water soaking, chemical soaking, convection oven heating) are used to remove support material, then the support material is removed from the object, but the processing time increases substantially especially as object size increases
Solution Approach 1:
The patent replaces conventional thermal convection heating with direct microwave irradiation to heat the support material. The microwave source directly couples energy to the support material through the circulator, eliminating the need for convection ovens and substantially reducing heating time while maintaining effective support material removal.
Solution Approach 2:
The patent introduces a circulator as an intermediary device between the microwave source and the object. The circulator directs microwave energy selectively to the support material while protecting the object from direct microwave exposure, enabling efficient support material removal without damaging the object.
2Loss of time
If microwave energy is applied to heat support material for removal, then processing time is reduced, but the object may be damaged by microwave energy
Solution Approach 1:
The circulator serves as a protective intermediary that directs microwave energy away from the object. It allows microwaves to pass through to heat the support material while reflecting or redirecting energy that would otherwise damage the object, enabling safe and efficient support material removal.
Solution Approach 2:
The patent applies microwave energy locally and selectively to the support material regions rather than uniformly to the entire object. The circulator enables targeted heating of support material while leaving the object protected, achieving localized thermal processing where needed.
3Productivity
If multiple objects are stacked in three-dimensions to increase production volume, then production capacity increases, but the amount of support material requiring removal increases substantially
Solution Approach 1:
The patent replaces slow conventional support material removal methods with rapid microwave heating, enabling efficient processing of large quantities of support material from multiple stacked objects. The direct microwave heating capability handles substantial support material volumes that would be impractical with water soaking or convection ovens.
Solution Approach 2:
The patent enables continuous processing of multiple stacked objects through the microwave system. The circulator allows sustained microwave irradiation to continuously heat and remove support material from multiple objects simultaneously, maintaining continuous productive action rather than batch processing.
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
Efficiently removes support material without damaging the object, significantly reducing processing time and improving production speed by using microwave energy to selectively heat support material based on its higher dielectric loss factor compared to the build material.
Implementation Method 1
irradiate the three-dimensional printed object having support material with microwave energy, the microwave energy heating the support material to a temperature at which the support material changes phase from a solid to a liquid
Implementation Method 2
generating with a temperature sensor a signal indicative of a temperature of the susceptor
Data Source
AI summary
A system uses microwave energy to remove support material from a three-dimensional printed object with reduced risk of damage to the object. The system includes a microwave source, a three port device, a susceptor, a temperature sensor, and a controller. The controller operates the microwave source to direct microwave energy into a first port of the three port device, which emits the microwave at a second port of the three port device to irradiate the three-dimensional object and melt the support material. Reflected microwave increases as the amount of support material contacting the object is reduced and enters the second port of the three port device, which directs the reflected energy to the susceptor coupled to a third port of the three port device. The controller monitors the signal generated by the temperature sensor and deactivates the microwave source in response to a predetermined condition being reached.