Removable Inserts for Additive Manufacturing Build Plates
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Solution Overview
Problem
The existing additive manufacturing processes are time-consuming and costly due to the need for separating components from build plates and grinding them down for reuse, which requires downtime for the manufacturing machine.
Innovation Solution
A method and system that utilize a build plate with indentations for multiple inserts, allowing components and support structures to be formed on separate inserts, enabling easy separation without electrical discharge machining, and allowing for quick replacement and reuse of inserts to minimize downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If components are built directly on the build plate, then the build plate provides a stable base for manufacturing, but the build plate must be removed, separated, and ground down after each component, causing machine downtime and increased cost
Solution Approach 1:
The build plate is segmented into a reusable base plate and removable inserts. The inserts are divided into primary inserts (for component building) and support inserts (for support structure building). This segmentation allows the base plate to remain in the machine while only the inserts are removed and replaced, eliminating the need to remove and re-machine the entire build plate.
Solution Approach 2:
The inserts are extracted from the build plate as separate, removable components. The primary insert and support inserts are placed into recesses in the build plate during manufacturing, then removed together with the component after building. This extraction allows the build plate to remain stationary and reusable while the inserts handle the manufacturing and separation functions.
2Ease of manufacture
If electrical discharge machining is used to separate components from the build plate, then separation is achieved, but the process is time-consuming and costly
Solution Approach 1:
The support structures are extracted as separate entities by building them on dedicated support inserts rather than directly on the build plate. This allows the support structures to be removed with the primary insert as a single unit, eliminating the need for time-consuming electrical discharge machining to separate them from the build plate.
Solution Approach 2:
The support inserts act as intermediaries between the build plate and the support structures. By providing a dedicated surface for support structure formation, the inserts facilitate easy separation of both the support structures and primary insert from the build plate without requiring complex machining operations.
3Ease of operation
If the build plate is ground down after each use, then it is prepared for the next manufacturing cycle, but this grinding process is costly and time-consuming
Solution Approach 1:
The build plate system is segmented into a permanent base plate and disposable/removable inserts. The base plate maintains its original surface and dimensions, eliminating the need for grinding. Only the inserts are removed and replaced, which do not require re-machining of the base plate itself.
Solution Approach 2:
The inserts are pre-prepared with the necessary surface characteristics for additive manufacturing before being placed in the build plate. This preliminary preparation of the inserts eliminates the need to re-machine or grind the build plate between manufacturing cycles, as the inserts provide the required surface for each new component.
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 reduces the time and cost associated with post-processing by allowing for efficient separation and reuse of inserts, thereby decreasing the overall manufacturing time and increasing the efficiency of the additive manufacturing process.
Implementation Method 1
a first energy source configured to change a state of the material to form the component and the first support structure
Data Source
Figure 1A~1D
Figure 2
AI summary
A system (10) and method (50) are disclosed for additively manufacturing a component that includes placing (54) a primary insert (20) and a first support insert (22A) into corresponding indentations (18) in a build plate of an additive manufacturing system, forming (58) the component (26) on the primary insert with the component having at least one overhang (32) located above the first support insert, and forming (60) a first support structure (30A) on the first support insert so as to be beneath the at least one overhang with the first support structure configured to support the at least one overhang. The method also includes, after the component has been formed, separating (64) the primary insert from the first support insert such that the first support structure is separated from the component.