Powdered Release Agent Dispensing for Additive Manufacturing

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Solution Overview

Problem

Current additive manufacturing methods face challenges in efficiently and effectively removing sacrificial supports from large-scale parts due to time-consuming mechanical and chemical processes, which can damage the part and become increasingly difficult with larger sizes.

Innovation Solution

An apparatus and method for generating and dispensing a powdered release agent between layers of a part using an additive manufacturing machine, comprising a housing with a grinder that powderizes a solid release agent material and a nozzle for precise dispensing, allowing for easy separation of supports from the part.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If mechanical and chemical means are used to remove sacrificial supports, then support removal is achieved, but the process becomes time-consuming and can damage the part

Engineering Contradiction:

Improvesupport removal efficiencyVSAvoidsupport removal time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The release agent is applied to the support structures during the additive manufacturing process before the part is complete. This preliminary application allows for easy removal later without time-consuming mechanical or chemical processes, directly resolving the contradiction between support removal efficiency and time consumption

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A powdered release agent serves as an intermediary substance between the support structures and the part layers. This powder reduces adhesion forces, enabling support removal without direct mechanical force or chemical solvents, thereby improving productivity while avoiding part damage and reducing removal time

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If mechanical and chemical means are used to remove sacrificial supports, then support removal is achieved, but the part can be unintentionally damaged

Engineering Contradiction:

Improvesupport removal efficiencyVSAvoidpart damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The powdered release agent acts as a protective intermediary that reduces the bonding strength between supports and part layers. This allows supports to be removed easily without applying mechanical force that could damage the part, resolving the contradiction between efficient support removal and part integrity

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The release agent is a consumable material applied in small amounts that performs its function of reducing adhesion and is then discarded during support removal. This disposable approach eliminates the need for damaging mechanical or chemical removal processes while protecting the part

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of manufacture

If solid release agent material is used directly, then material handling is simple, but dispensing consistency is poor due to spillage

Engineering Contradiction:

Improvematerial handling simplicityVSAvoidpowder dispensing consistency

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The system changes the physical state of the release agent from solid blocks to powder form through a grinder. This parameter change allows the material to be dispensed as a controlled powder stream rather than requiring direct handling of solid material, resolving the contradiction between handling simplicity and dispensing precision

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The manual or mechanical handling of solid release agent is replaced by an automated grinding and pneumatic dispensing system. The grinder converts solid material to powder, and a pneumatic system delivers it precisely to the build area, eliminating spillage while maintaining ease of operation through automation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 powdered release agent improves the efficiency of support removal, saving time and preventing damage to the part by reducing adhesion between layers, and eliminating issues like spillage and inconsistent dispensing.

Implementation Method 1

A grinder disposed inside of the grinding chamber powderizes the release agent material

Methodology Applied

Scientific EffectMechanical abrasion: Abrasion

Data Source

PatentUS10780612B2Method for generating and dispensing a powdered release agent

Publication Date: 2020.09.22 UT BATTELLE LLC

AI summary

A method 100 for generating and dispensing a powdered 60 release agent during an additive manufacturing build is disclosed. A solid body 28 of release agent material is ground insitu by a grinder 50 and dispensed on a surface of the part 72 to prevent adhesion of an adjacent layer of a base material 70. With the addition of the powdered 60 release agent, a support structure 76 is easily separated from the base material 70 when the part 72 is complete, saving time and preventing the part 72 from sustaining unintentional damage. Since no powdered 60 release agent is actually loaded or stored in the apparatus 20, the potential for spillage, waste, inconsistent dispensing, inadvertent dispensing, and clumping due to humidity is eliminated.