Additive Manufacturing Removal Tool for Blind Surface Support
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Solution Overview
Problem
The removal of support structures and materials in additive manufacturing is a time-consuming and difficult process, especially for complex geometries where support material is enclosed or obscured by the finished part structure.
Innovation Solution
A method and system for generating a support material removal tool that includes designing a removal tool with a contact surface and a paring surface intersecting at a leading edge, which is fabricated alongside the additively manufactured component, allowing for efficient separation of support material from blind design surfaces using an additive manufacturing machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If support structures are used during additive manufacturing, then manufacturing reliability is improved, but support material removal becomes time-consuming and difficult
Solution Approach 1:
The patent applies preliminary action by designing and fabricating the removal tool alongside the main component during the additive manufacturing process itself. The removal tool is prepared in advance with specific geometric features (contact surface, paring surface, leading edge) that enable efficient support material removal before the component is fully completed, thereby reducing the time required for post-processing support removal.
2Manufacturing precision
If support material is used to enclose blind design surfaces, then manufacturing precision is improved, but ease of operation deteriorates
Solution Approach 1:
The patent introduces an intermediary removal tool that mediates between the support material and the blind design surface. The removal tool includes a contact surface that interfaces with the support material and a paring surface with a leading edge that carefully separates the support material from the blind design surface. This intermediary tool enables precise removal of support material from enclosed areas without damaging the underlying geometry, thereby maintaining manufacturing precision while improving ease of operation.
3Device complexity
If manual removal methods are used for support material, then device complexity is reduced, but productivity decreases
Solution Approach 1:
The patent applies self-service by designing the removal tool to be self-contained and self-sufficient for the support material removal task. The tool includes all necessary features (contact surface, paring surface, leading edge, tabs for manipulation) integrated into a single component that can be manually operated without requiring complex external equipment or systems. This simple yet effective design maintains low device complexity while significantly improving productivity compared to traditional manual removal methods.
Data Source
AI summary
A method of manufacturing an additively manufactured component may comprise operating an additive manufacturing machine to form a first structure including an elongate portion having a blind design surface, operating the additive manufacturing machine to form a removal tool proximate the blind design surface, wherein the blind design surface and the removal tool are at least partially enclosed by and in contact with a support material, and translating the removal tool along the blind design surface to separate a portion of the support material from the blind design surface.