Reusable Supporting Platform for Additive Manufacturing Build Plates
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Solution Overview
Problem
Conventional additive manufacturing systems rely on disposable supports that are costly, cumbersome, and require frequent machining of build plates, leading to increased production time and expenses due to the need for frequent replacement of build plates and supports, especially with complex geometries and secondary functions.
Innovation Solution
A reusable supporting platform is integrated into the additive manufacturing process, allowing components to be built on a base plate with a top surface that includes a body with a first surface coupled to the plate and a second surface for supporting components, enabling the reuse of the platform after component separation, thus reducing the need for frequent machining and replacement of build plates and supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If disposable supports are used on the build plate, then component removal is simplified, but the build plate requires frequent machining and replacement, increasing production time and cost
Solution Approach 1:
The build plate system is segmented into a permanent build plate and disposable supports. The supports are designed as separate, removable components that can be easily detached after component fabrication, while the build plate itself remains intact and reusable, eliminating the need for frequent machining and replacement of the entire build plate assembly.
Solution Approach 2:
Disposable supports are used instead of reusable build plates. The supports are designed to be inexpensive, single-use components that are sacrificed during the component removal process, while the expensive build plate is preserved and can be reused multiple times without machining, thereby reducing overall production time and cost.
2Manufacturing precision
If conventional build plates are used, then components can be built with identical physical attributes to machined components, but the build plate operational life decreases and replacement is required
Solution Approach 1:
The build plate system is divided into a permanent, durable build plate and disposable supports. This segmentation allows the build plate to maintain its structural integrity and precision surface over multiple uses, while the disposable supports absorb the wear and damage during component removal, thereby extending the operational life of the build plate without compromising manufacturing precision.
Solution Approach 2:
The disposable supports are discarded after use, while the build plate is recovered and reused. This approach preserves the expensive build plate for multiple fabrication cycles, extending its operational life, while the inexpensive supports are sacrificed to maintain the build plate's integrity and precision surface.
3Ease of operation
If disposable supports are sacrificed and removed, then component separation is simplified, but the supports cannot be reused and must be discarded
Solution Approach 1:
The supports are designed as inexpensive, single-use components made from cost-effective materials. Their disposability simplifies component separation, and their low cost makes the loss of material economically acceptable, turning what would be a waste problem into an economically viable solution.
Solution Approach 2:
The disposable supports are discarded after facilitating component removal, while the valuable build plate is recovered and reused. This approach accepts the loss of support material as an economical trade-off for preserving the expensive build plate and simplifying component separation operations.
4Productivity
If build plates are machined after each component build, then the build plate can be reused, but the machining process is expensive and increases production time
Solution Approach 1:
Disposable supports are used to protect the build plate from damage during component fabrication and removal. Since the supports are sacrificial and inexpensive, they absorb the wear and stress that would otherwise require expensive machining operations to restore the build plate surface, enabling reuse without machining.
Solution Approach 2:
The disposable supports are discarded after use, while the build plate is recovered in its original condition without requiring machining. This approach eliminates the expensive and time-consuming machining process, allowing immediate reuse of the build plate and significantly reducing manufacturing costs and production time.
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 solution significantly reduces production costs and time by allowing multiple components to be manufactured on a single reusable platform, extending the operational life of build plates and minimizing waste, while maintaining the physical attributes of conventionally machined components.
Implementation Method 1
performing a material transformation process, such as sintering or melting, on the powder material
Implementation Method 2
performing a material transformation process, such as sintering or melting, on the powder material
Data Source
AI summary
A method for using a build plate including a reusable supporting platform for additive manufacturing of a component is disclosed. The method may include additive manufacturing the reusable supporting platform on a top surface of a base of the build plate, and additive manufacturing a first component on the second surface of the reusable supporting platform. The method may also include separating the first component from the build plate at the second surface of the reusable supporting platform, thereby exposing a new surface of the body of the reusable supporting platform. Additionally, the method may include additive manufacturing at least a second component on the new surface of the reusable supporting platform. The reusable supporting platform may include a body including a first surface coupled to the top surface of the base of the build plate, and a second surface configured to support a component to be formed by additive manufacturing and for separation of the component from the build plate.