Recyclable Particle Tank for Additive Manufacturing Support
Solution Overview
Problem
Existing additive manufacturing methods using material layering with extrusion require costly and resource-intensive support structures that often cause surface deformations and increase production costs due to material waste and separation difficulties.
Innovation Solution
The method employs a recyclable particle tank filled with materials like fine sand powders for support structures, allowing for controlled cooling and re-use of materials, reducing costs and enhancing surface quality, particularly for lattice structures with voids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If support structures are made of the same material as the manufactured part and separated by cutting, then separation is enabled, but severe deformations occur on the surface quality of the actual part
Solution Approach 1:
The invention extracts the support structure material from the main part material by using a recyclable particle tank with separate support particles. The support structures are formed from loose particles that can be easily removed without contact with the main part, eliminating surface deformations caused by cutting while maintaining separation capability.
Solution Approach 2:
The invention introduces an intermediary medium (recyclable particle tank with support particles) between the extrusion system and the build platform. This intermediary allows support structures to be formed and then easily separated through particle removal mechanisms without directly cutting the main part, thus preserving surface quality.
2Ease of manufacture
If support structures are made of water soluble material, then separation is enabled without cutting, but product material costs increase and materials are lost
Solution Approach 1:
The invention implements a recyclable particle tank where support structure particles are discarded after use and then recovered through the recyclable tank system. The particles are reused for subsequent support structures, eliminating material waste while maintaining easy separation through the particle-based system.
Solution Approach 2:
The recyclable particle tank serves multiple functions: it stores support particles, enables support structure formation, facilitates easy separation, and allows particle recycling. This multi-functional system replaces the need for specialized water-soluble materials with a versatile particle-based approach that eliminates material loss.
3Manufacturing precision
If additive manufacturing is carried out inside a particle tank, then controlled cooling is enabled and surface quality is enhanced, but the workpiece must have at least one material discharge hole
Solution Approach 1:
The invention segments the workpiece design by requiring at least one discharge hole for material removal. This segmentation allows the particle tank system to cool the workpiece uniformly from all sides while providing a designated exit path for support particles, enabling controlled cooling and enhanced surface quality with manageable design 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
This approach reduces manufacturing costs by reusing support materials, improves surface quality through controlled cooling, and simplifies the production of complex structures like lattice structures with voids, while ensuring environmental and health safety.
Implementation Method 1
the hot molten material which enables production of the actual part shall be able to cool down in a controlled manner. The homogenous cooling environment, ensures the structure of the actual part to be more durable and the surface quality to be enhanced.
Data Source
Figure 1
AI summary
The invention subject to the application is related to a method of establishing support structures used in additive manufacturing methods based on the material layering with extrusion principle with 3D printers, wherein the method is characterized in that additive manufacturing carried out by material layering with extrusion is performed in a recyclable particle tank (powder, sand, particle etc.).