Removable Mount for 3D Printing Complex Geometries
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Solution Overview
Problem
The challenge in 3D printing is the complexity in configuring and placing support structures for parts with intricate geometries, leading to material waste and increased costs, as existing methods struggle to efficiently manufacture parts with features like flanges or extensions.
Innovation Solution
A method and system that utilize a reusable mount secured to the platform, allowing for the application of additional layers of material to form flanges and extensions, with the mount being removable after completion, enabling the construction of complex geometries while minimizing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional support structures are used to manufacture parts with complex geometries, then the part can be formed, but material waste increases and costs increase
Solution Approach 1:
The patent introduces a removable mount as an intermediary object that facilitates the formation of complex geometries (such as flanges and extensions) during the 3D printing process. The mount serves as a temporary surface onto which material can be deposited for features that would otherwise require traditional support structures. After printing, the mount is removed cleanly without leaving residue or causing material waste, thus enabling complex geometries while minimizing material loss.
2Shape
If traditional support structures are used to form flanges and extensions, then the part geometry can be achieved, but the support structures must be removed which may break or tear the part
Solution Approach 1:
The removable mount acts as an intermediary that is specifically designed to be detached without damaging the part. Unlike traditional support structures that are integrally connected and require breaking or tearing away, the mount is positioned and configured to allow clean removal after the printing process, thereby preserving part integrity while still enabling the formation of complex geometries like flanges and extensions.
Solution Approach 2:
The patent extracts the function of support structures from being permanently integrated into the part and instead uses a separate, removable mount. This extracted support function is performed by the mount during printing, then the mount is taken out (removed) cleanly, leaving no damaging removal process on the final part. This separation of the support function from the final part structure prevents breaking or tearing during removal.
3Loss of substance
If reusable mounts are used instead of disposable support structures, then material waste is reduced, but the device complexity increases
Solution Approach 1:
The removable mount is designed as a universal component that can be reused across multiple printing jobs and adapted to different part geometries. Instead of creating new support structures for each print, the same mount can be repositioned or reconfigured to serve multiple functions for various complex features (flanges, extensions, etc.). This universality reduces material waste while the standardized mount design actually simplifies the overall process compared to creating custom support structures for each part.
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 enables the efficient manufacturing of parts with complex geometries by reducing material waste and costs, as the reusable mount allows for the formation of features like flanges without breaking or tearing the part, and can be reused, thereby optimizing the 3D printing process.
Implementation Method 1
a light source configured to emit light to cure the liquid polymer
Implementation Method 2
a plurality of filaments and sintering the filaments to form each layer of the first plurality of layers in a laser sintering process
Data Source
AI summary
A method for manufacturing a part includes applying a first plurality of layers of material to a surface, inserting a mount onto the surface, applying a second plurality of layers of material onto the first plurality of layers and onto the mount, and removing the mount upon application of the second plurality of layers.