Additive Fabrication Raft Structure with Removal Pockets
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Solution Overview
Problem
In additive fabrication, such as 3D printing, post-processing steps often risk damaging fabricated parts due to inadequate adhesion between the part and the build surface, requiring excessive force for removal, which can lead to part damage or user injury, especially when high adhesive forces are involved.
Innovation Solution
A raft structure with removal pockets is formed on the build platform to increase adhesion during fabrication, allowing for easier and safer part removal by providing a larger surface area and strategically designed void spaces for tool insertion, reducing the force required for separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If high adhesive forces are used between the part and build surface, then part stability during fabrication is improved, but part removal becomes difficult and risks damage
Solution Approach 1:
The build surface is segmented into multiple discrete adhesion points (adhesion features) rather than a continuous adhesive surface. This segmentation allows the part to be firmly held during fabrication while providing specific localized points for tool insertion during removal, resolving the contradiction between stability and ease of removal.
Solution Approach 2:
Adhesion features act as intermediary elements between the part and build surface. These features provide controlled adhesion during fabrication but can be selectively engaged by removal tools, serving as a mediator that enables both stable fabrication and easy removal without direct conflict between these opposing requirements.
2Force
If excessive force is applied for part removal, then part separation from build surface is achieved, but part damage or user injury occurs
Solution Approach 1:
The adhesion features are extracted as distinct, removable elements from the build surface. This extraction allows removal tools to engage specific features and progressively detach the part, distributing the separation force across multiple controlled interactions rather than requiring a single high-force action that could cause damage or injury.
Solution Approach 2:
Adhesion features are designed in advance with geometry that facilitates controlled removal. The features are pre-configured to be engageable by standard removal tools, allowing the removal process to begin with low force and progressively increase as needed, preventing the need for sudden excessive force application.
3Area of stationary object
If large surface area contact is used between part and build surface, then adhesion strength is improved, but removal difficulty increases
Solution Approach 1:
The contact surface area is segmented into multiple discrete adhesion features rather than a continuous large-area contact. This segmentation maintains sufficient total adhesion strength through the cumulative effect of multiple features while providing accessible edges and geometry that enable tool insertion for removal, resolving the contradiction between adhesion strength and removal ease.
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 raft structure enhances stability and adhesion during fabrication without altering the final part's form, enabling safer and more efficient post-processing by allowing lower force separation, thus minimizing the risk of part damage and user injury.
Implementation Method 1
A raft structure with removal pockets is formed on the build platform to increase adhesion during fabrication
Data Source
AI summary
According to some aspects, a method of additive fabrication wherein a plurality of layers of material are formed on a build platform is provided. The method comprises forming a raft structure in contact with the build platform, the raft structure formed from one or more layers of material and comprising at least one removal pocket adjacent to the build platform and forming additional material in contact with the raft structure. According to some aspects, an additive fabrication apparatus configured to form a plurality of layers of material on a build platform is provided. The apparatus comprises the build platform, and at least one controller configured to form a raft structure in contact with the build platform, the raft structure formed from one or more layers of material and comprising at least one removal pocket adjacent to the build platform, and form additional material in contact with the raft structure.