3D Printer Actuator for Automated Part Release
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Solution Overview
Problem
Current methods for removing three-dimensional printed parts from a build platen are cumbersome, time-consuming, and risk damaging the part or the platen, lacking efficiency and automation.
Innovation Solution
A three-dimensional object printer with a platen and an actuator system, where a controller operates an ejector head to form the object and applies a force using a stack or strip actuator to break adhesion between the object and the platen, facilitating easy release through vibration or bending of the platen.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional methods (heating, impacting, scraping, freezing) are used to remove printed parts from the platen, then the part can be removed from the platen, but the process is cumbersome, time-consuming, and risks damaging the part or platen
Solution Approach 1:
The patent replaces traditional mechanical removal methods (heating, impacting, scraping, freezing) with an acoustic field-based approach using ultrasonic vibrations. The ultrasonic transducer generates high-frequency mechanical vibrations that create acoustic radiation pressure and cavitation effects in the liquid medium, enabling part release without direct mechanical contact or thermal treatment.
Solution Approach 2:
The patent introduces a liquid medium as an intermediary between the ultrasonic transducer and the printed part. This liquid medium transmits ultrasonic energy to the part-platen interface, facilitating adhesion breakdown through acoustic cavitation and microstreaming effects, while protecting both the part and platen from direct mechanical stress.
2Extent of automation
If manual removal methods are used, then flexibility is maintained, but automation and manufacturing efficiency are reduced
Solution Approach 1:
The system enables automated part removal through a self-regulating process where ultrasonic vibrations automatically break the adhesion between the printed part and platen. The liquid medium and ultrasonic field work together to create conditions where the part releases itself without requiring manual intervention, scraping, or additional mechanical forces.
Solution Approach 2:
The patent applies ultrasonic vibrations and liquid medium treatment before any physical part removal occurs. This preliminary acoustic treatment weakens the adhesion bonds between the printed part and platen, preparing the interface for easy, damage-free separation and enabling subsequent automated handling.
3Reliability
If strong forces are applied to break adhesion, then part removal is achieved, but damage to the part or platen may occur
Solution Approach 1:
The patent employs ultrasonic vibrations (high-frequency mechanical oscillations) to break adhesion between the printed part and platen. These vibrations create dynamic stresses at the interface that progressively weaken adhesive bonds through fatigue and cavitation effects, enabling part release with minimal peak forces and without impacting or scraping the surfaces.
Solution Approach 2:
The ultrasonic energy induces localized phase transitions in the liquid medium through acoustic cavitation (formation and collapse of microbubbles). This cavitation process generates intense localized effects that break adhesion bonds without requiring high mechanical forces, protecting both the printed part and platen from damage.
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
Enables fast, reliable, and automated removal of three-dimensional printed parts without damaging them or the platen, improving manufacturing efficiency by breaking adhesion effectively.
Implementation Method 1
break adhesion between the bottom layer of the three-dimensional object and the platen
Implementation Method 2
deliver an electrical signal to the planar actuator to bend the planar actuator and release the three-dimensional object from the planar actuator
Data Source
AI summary
A three-dimensional object printer includes an actuator that contacts a surface of a platen in the printer. A controller selectively operates the actuator to apply force to a bottom layer of a three-dimensional object formed on the platen to break an adhesion between the bottom layer and the platen.