Removable Support Blocks for Additive Manufacturing Plates
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Solution Overview
Problem
The removal of 3D-printed articles with their supports from the support plate is difficult and time-consuming, leading to inefficiencies in resurfacing the plate for subsequent printing processes.
Innovation Solution
A method and assembly that utilize a support plate with block engagement locations and removably engageable support blocks, allowing for easy attachment, printing, and detachment of articles, followed by machining and resurfacing of the support plate for reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If articles are 3D-printed simultaneously on a single support plate with integral supports, then productivity is improved by printing multiple articles at once, but the removal of assemblies from the support plate becomes difficult and time-consuming
Solution Approach 1:
The support plate is divided into multiple removable support blocks that can be individually detached from the plate. Each support block can be selectively removed with its printed article, simplifying the removal process while maintaining the ability to print multiple articles simultaneously on the same plate.
Solution Approach 2:
The support blocks are made removable from the support plate through engagement mechanisms (such as magnets, clips, or mechanical interlocks). This allows the support blocks with printed articles to be easily extracted from the plate without requiring difficult cutting or breaking operations, thus improving ease of operation while maintaining productivity.
2Manufacturing precision
If articles are printed with integral supports on the support plate, then manufacturing precision is maintained, but the resurfacing of the support plate becomes time-consuming and expensive
Solution Approach 1:
The support blocks are designed as disposable or easily replaceable components. After use, they can be quickly removed and replaced with fresh support blocks without requiring resurfacing of the main support plate. This dramatically reduces the time and cost associated with plate maintenance while preserving printing precision.
Solution Approach 2:
Instead of resurfacing the entire support plate, the worn or contaminated support blocks are discarded and replaced with new ones. The support plate itself is preserved and can be reused repeatedly, minimizing downtime and maintenance costs while maintaining consistent printing accuracy across multiple production cycles.
3Manufacturing precision
If the support plate is resurfaced after each printing cycle, then manufacturing precision is maintained, but productivity is reduced due to time loss
Solution Approach 1:
By segmenting the support plate into multiple removable support blocks, only the individual blocks need to be replaced rather than the entire plate being resurfaced. This maintains surface quality for printing while minimizing operational downtime, thus preserving productivity.
Solution Approach 2:
Fresh support blocks are prepared in advance and can be quickly swapped in when needed. This preliminary preparation eliminates the need for time-consuming resurfacing operations during production cycles, maintaining both surface quality and productivity.
Data Source
AI summary
There is disclosed a method for printing an article by additive manufacturing comprising providing an additive manufacturing system and a support plate having a block engagement location; engaging a support block having an article-printing surface with the support plate at the block engagement location; engaging the support plate with the additive manufacturing system; additive manufacturing an article on the article printing surface of the support block engaged with the support plate; and disengaging, from the support plate, the support block having the article printed thereon. There is also disclosed corresponding additive manufacturing support assembly, additive manufacturing kit and additive manufacturing assembly.