Conformal Pin Array Support for 3D Print Part Extraction
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Solution Overview
Problem
Current 3D additive printing methods face challenges in efficiently and gently removing completed parts from build plates without damaging either the parts or the plates, often requiring tedious and potentially harmful processes like scraping or elaborate machinery.
Innovation Solution
A pin array apparatus with movable, spring-biased pins that conform to the build part's contour and lock in place using an elastomeric locking mechanism, allowing for stable support and easy extraction of the part, even when inverted for etching processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If scraping is used to remove the 3D print from the build plate, then the part can be removed, but damage occurs to the 3D print or the build plate surface
Solution Approach 1:
A release film is introduced as an intermediary layer between the build plate and the printed part. The film allows the part to be printed directly onto it, and then the entire film with the part can be easily removed from the build plate without scraping, thus preventing damage to both the part and the build plate surface.
2Ease of operation
If EDM wire is used to excise the 3D printed part, then the part can be removed, but damage occurs to the build part and build plate, and elaborate machinery is required
Solution Approach 1:
The release film serves as a mediator that simplifies the removal process. Instead of using complex EDM machinery to cut the part free, the part is printed on the film which can then be easily peeled or cut from the build plate, dramatically reducing device complexity while preventing damage.
3Ease of manufacture
If chemical etching is used to remove sacrificial support, then the support can be removed, but precise timing is required and the build piece dimensions must account for sacrificial thickness
Solution Approach 1:
The release film is designed as a sacrificial material that is discarded after serving its purpose. The film is removed along with the sacrificial support material during the cleaning process, eliminating the need for precise timing control of chemical etching and simplifying the manufacturing process while maintaining dimensional accuracy of the final part.
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 solution simplifies the extraction process, reduces damage risk, and enables efficient removal of sacrificial interposers, facilitating the reuse of build plates and the pin array, while providing stable support during etching.
Implementation Method 1
The pins can be spring-biased to press the pins into solid contact with the build part
Implementation Method 2
As the composition is compressed, the Poisson effect causes the elastomeric composition to press against the pins within the holes in the composition, to thereby lock the pins by friction
Implementation Method 3
lock the pins by friction between the pins and the compressed elastomeric composition
Data Source
AI summary
An apparatus and method are provided for extracting a build part from an additive manufacturing machine. Upon completion of the build part by the additive manufacturing machine, a pin array is placed above the build part, the pin array including a plurality of pins slidably supported by a support plate for vertical movement relative to the support plate. The pin array is moved toward the build part so that the plurality of pins contact the build part and conform to the contour of the build part. The pins of the pin array are locked with the pins in contact with and conforming to the build part. The pin array and build part are inverted so that the build part is supported by the locked pins of the pin array. All of the pins of the array are locked simultaneously by a common locking component. The build plate can be formed on a sacrificial interposer plate that is removed by an etchant bath supported on the pin array when the build part is inverted.