Peeling Device for Additive Manufacturing Separation Forces
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Solution Overview
Problem
During the tape casting process in additive manufacturing, components often break due to forces encountered during separation from the resin support, leading to delamination and breakage.
Innovation Solution
An additive manufacturing apparatus is designed with a peeling device positioned downstream of the window, allowing the stage and resin support to move simultaneously over the peeling device in the X-axis direction, minimizing separation forces and reducing the likelihood of component breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the stage and resin support are separated during the tape casting process, then the component can be built layer by layer, but component breakage occurs due to separation forces
Solution Approach 1:
A peeling device is introduced as an intermediary element between the stage and resin support. This device includes a peeling surface that the cured layer contacts during separation, allowing the layer to be peeled from the resin support in a controlled manner that minimizes breakage of fine features
Solution Approach 2:
The system transitions from static separation to dynamic peeling by moving the peeling device relative to the stage and resin support. The peeling device can move in the X-axis direction to facilitate controlled separation, transforming the separation process into a dynamic operation that reduces harmful forces
2Device complexity
If traditional separation methods are used, then the process is simple, but delamination and breakage occur
Solution Approach 1:
The peeling device serves as a mediator that improves manufacturing precision during separation. By introducing this intermediate element with a specifically designed peeling surface, the system achieves better control over the separation process without requiring complex additional mechanisms
Solution Approach 2:
The peeling device changes the physical parameters of the separation process by providing a controlled peeling surface with specific friction and adhesion characteristics. This alters the separation mechanics from direct pulling to controlled peeling, reducing stress on fine features
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 apparatus effectively minimizes component breakage by enabling localized and controlled separation from the resin support, enhancing the production of complex components with fine features without delamination.
Implementation Method 1
Radiant energy is produced from a radiant energy device and directed through a window to cure the resin to a component that is supported by a stage in the build zone
Data Source
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AI summary
An additive manufacturing apparatus (10) includes a support plate (14) and a stage (18) configured to hold a component (12) formed of one or more cured layers of a resin (R). An actuator assembly (38) is configured to change a relative position of the stage (18) relative the support plate (14). A radiant energy device (20) is positioned opposite to the stage (18) such that it is operable to generate and project radiant energy in a pattern. A peeling device (64) is positioned downstream of the window (16). The actuator assembly (38) is configured to move the stage (18) simultaneously with a resin support (26) over the peeling device in an X-axis direction.