3D Printed Part Cleaning Using Foil Translation and Slurry Shear
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Solution Overview
Problem
Conventional additive manufacturing methods face challenges in achieving dimensional accuracy and uniform surface finishes due to residual cured or partially cured materials adhering to the build surface, which can disrupt the layered structure and mechanical properties of printed components.
Innovation Solution
A method involving a transparent foil sheet and electromagnetic source is used to cure photopolymer resin, followed by a cleaning process that applies an abrasive shear force through a slurry to remove partially cured materials without mechanical scraping or solvents, ensuring uniformity and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive manufacturing processes are used without cleaning, then the printing process continues uninterrupted, but residual cured or partially cured materials adhere to the build surface causing surface roughness and dimensional inaccuracy
Solution Approach 1:
The patent replaces mechanical scraping or solvent-based cleaning systems with an acoustic field (ultrasonic vibration) to remove residual cured materials. The ultrasonic vibrations generate cavitation and mechanical stress in the liquid medium, which selectively removes contaminated material from the build surface without affecting the cured part, thereby resolving the contradiction between maintaining manufacturing precision and eliminating surface roughness.
Solution Approach 2:
The patent introduces a liquid medium as an intermediary between the build surface and the removal mechanism. This liquid medium facilitates the acoustic cleaning process by transmitting ultrasonic vibrations and enabling cavitation, allowing effective removal of residual materials while preserving the integrity of the printed part and maintaining dimensional accuracy.
2Object-generated harmful factors
If mechanical scraping is used to clean the build surface, then contaminants are removed, but the printed part or portions thereof may be unintentionally removed
Solution Approach 1:
The patent replaces direct mechanical contact scraping with an acoustic field-based cleaning mechanism. The ultrasonic vibrations transmitted through the liquid medium create cavitation bubbles and micro-jets that selectively erode and remove contaminated material from the build surface without requiring direct mechanical contact with the printed part, thus preventing unintentional removal of part material and maintaining part integrity.
Solution Approach 2:
The patent applies cleaning energy locally to the build surface through the liquid medium. The ultrasonic vibrations and cavitation effects are concentrated at the liquid-solid interface where contaminants are present, creating localized cleaning action that removes contaminants while leaving the cured part material unaffected, thereby preserving part integrity while achieving effective contaminant removal.
3Object-generated harmful factors
If cleaning fluids are used to remove unwanted materials, then the build surface is cleaned, but residual cleaning fluid may contaminate the cast layer
Solution Approach 1:
The patent replaces solvent-based chemical cleaning with an acoustic field-based physical cleaning mechanism. Ultrasonic vibrations transmitted through the liquid medium create cavitation and mechanical stress that remove contaminants from the build surface without requiring additional cleaning fluids, thereby achieving effective build surface cleaning while eliminating the risk of fluid contamination to the cast layer.
Solution Approach 2:
The patent uses the liquid medium already present in the additive manufacturing process as the transmitting medium for ultrasonic vibrations. This eliminates the need for separate cleaning fluids, as the process liquid itself facilitates the cleaning action through acoustic cavitation, thereby achieving build surface cleanliness without introducing additional contamination risks from cleaning fluids.
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 enhances the accuracy and surface finish of printed parts by removing contaminants effectively, maintaining mechanical properties and avoiding post-processing steps, while allowing for distinct material segregation between layers.
Implementation Method 1
exposing the cast layer to radiant energy to form a segment of a printed part on the build surface
Implementation Method 2
a cleaning process that applies an abrasive shear force through a slurry to remove partially cured materials
Data Source
AI summary
A method for cleaning an additively manufactured part, the method comprising: contacting a cast layer with a build plate. The cast layer is disposed on a first side of a foil sheet and has a surface height spaced vertically above the foil sheet along a first axis. The build plate is vertically spaced above the foil sheet along the first axis. The method includes moving the build plate along the first axis to position a build surface at a cure depth below the surface height of the cast layer to form a segment of a printed part on the build surface. The method includes moving the build plate along the first axis to position the segment of the printed part above the cure depth and translating the foil sheet along a second axis to clean the segment of the printed part within the cast layer.