Pressurized Flexible Hose for Internal 3D Print Support Removal
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Solution Overview
Problem
The removal of internal support structures from additively manufactured parts is challenging due to their complex and small-scale nature, making mechanical removal difficult and requiring expensive chemicals that are not reusable.
Innovation Solution
A flexible hose with a bendable and elongated tube member, equipped with an internal channel and a fracturing member, is inserted into the part. The hose is pressurized, causing it to flail and break the internal support structures, or a balloon is inflated to fracture the supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If chemical solvents are used to remove internal support structures, then the support structures can be removed from complex internal portions, but the solvents are expensive and require disposal
Solution Approach 1:
The patent replaces chemical solvents with a mechanical system consisting of a flexible hose that can be inserted into internal portions of the part. The hose is pressurized with fluid to cause it to flail and mechanically break apart the support structures, eliminating the need for expensive chemical solvents and their associated disposal requirements.
Solution Approach 2:
The patent uses pressurized fluid (pneumatic or hydraulic system) to drive the flexible hose. The pressurized fluid causes the hose to flail and move erratically, enabling it to reach and break support structures in complex internal geometries without requiring chemical solvents.
2Ease of manufacture
If mechanical means are used to remove support structures, then the removal process is simple, but internal support structures are encased and not easily reached
Solution Approach 1:
The patent uses a flexible hose that can bend and navigate through complex internal geometries of the additively manufactured part. This flexible structure allows the system to reach encased internal support structures that would be inaccessible to rigid mechanical removal tools, while still enabling simple mechanical breaking of the supports.
3Strength
If the hose is made rigid to provide structural support, then it can withstand pressurization, but it cannot navigate complex internal geometries
Solution Approach 1:
The patent employs a flexible hose construction that combines flexibility for navigation with sufficient strength to withstand pressurization. The hose can bend and conform to complex internal geometries while maintaining the structural integrity needed to handle pressurized fluid and mechanically break support structures.
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 solution allows for the efficient and cost-effective removal of internal support structures from additively manufactured parts, using reusable and inexpensive materials, and avoids the disposal issues associated with chemical solvents.
Implementation Method 1
the tube member includes an internal channel with an inlet and an outlet, the internal channel configured for fluid flow from the inlet to the outlet, wherein the inlet is configured to receive the fluid flow from a pressurized source, and the outlet is configured to cause the tube member to flail upon egress of the fluid flow from the outlet
Implementation Method 2
the hose further includes a fracturing member, the fracturing member configured to fracture an internal support structure within the hollow portion of the additively manufactured part during the flailing of the tube member
Implementation Method 3
the hose includes a balloon secured to the outlet so than an inflatable interior is configured to receive a portion of the fluid flow from the pressurized source such that the portion of the fluid flow causes the balloon to inflate
Implementation Method 4
the method includes applying the pressurized fluid to the inlet to cause the balloon to inflate, whereby the inflation causes the balloon to fracture the support structure
Data Source
AI summary
Apparatus and methods for removing and/or destroying support structures associated with objects fabricated using additive manufacturing techniques are presented herein. Structural supports may be used during an additive manufacturing process to prevent deformation of a build piece (e.g., three dimensional (3D) printed structure). In some examples, a build piece may be manufactured such that the structural supports are internal to the completed build piece. However, removing the structural supports may reduce the weight of the build piece and reduce the amount of debris trapped within the build piece. Thus, certain aspects of the disclosure are directed to a hose including a bendable and elongated tube member as well as a fracturing member configured to fracture an internal support structure within an additively manufactured part.