Rotor-Based Additive Manufacturing Post-Processing With Sensor Feedback
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Solution Overview
Problem
Conventional techniques for removing excess material from additively manufactured objects, particularly those made with highly viscous resins and having complex geometries, are inadequate in scalability and integration with other post-processing steps.
Innovation Solution
A system is developed that includes a rotor for spinning additively manufactured objects to remove excess material, with additional components for temperature management and energy application to alter material properties, and sensors for feedback-controlled operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional techniques are used to remove excess material, then the process is simple, but it is insufficient for highly viscous resins and complex geometries
Solution Approach 1:
The patent combines multiple post-processing operations (excess material removal, curing, temperature control) into a single integrated system. The build platform serves multiple functions: supporting objects during printing, rotating for centrifugal separation, heating for viscosity control, and positioning for sensor feedback. This merging resolves the contradiction by achieving reliable multi-step processing without proportionally increasing device complexity.
Solution Approach 2:
The build platform is designed as a multi-functional component that performs excess material removal through centrifugal force, provides temperature control to manage resin viscosity, supports multiple objects simultaneously, and integrates sensor feedback for automated control. This universality allows the system to handle highly viscous resins and complex geometries effectively while maintaining operational simplicity.
2Manufacturing precision
If conventional cleaning techniques are used, then the equipment is simple, but it cannot handle complex geometries or delicate parts effectively
Solution Approach 1:
The system uses centrifugal force generated by rotating the build platform to create effective separation between excess material and complex geometries. This mechanical action, combined with temperature-controlled resin manipulation, enables thorough cleaning of delicate parts and complex structures without requiring complex manual intervention, thus maintaining ease of operation while improving manufacturing precision.
3Productivity
If conventional techniques are used for material removal, then the process is straightforward, but it is not scalable for large amounts of objects
Solution Approach 1:
The build platform is designed to hold and process multiple objects simultaneously in an organized array. The centrifugal separation mechanism operates on all objects at once during rotation, and the temperature control system manages all objects uniformly. This segmentation approach enables scalable processing of large quantities of objects through a single automated operation, improving productivity without requiring proportionally complex equipment.
4Adaptability or versatility
If no sensor feedback is used, then the system is simple, but it lacks integration with other post-processing steps
Solution Approach 1:
The system incorporates sensors that detect object position, material state, and process parameters, providing feedback to control the build platform rotation speed, temperature, and other operational parameters. This feedback mechanism enables automated integration of multiple post-processing steps (removal, curing, temperature control) into a coordinated sequence, improving adaptability and versatility while managing system complexity through intelligent control rather than mechanical complexity.
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
The system effectively cleans objects with complex geometries and viscous materials, integrating multiple post-processing operations for improved efficiency and scalability.
Implementation Method 1
a rotor configured to support a plurality of additively manufactured objects and spin the rotor so as to remove the excess material from the plurality of additively manufactured objects
Implementation Method 2
a temperature management mechanism configured to produce a dynamic temperature profile that decreases a viscosity of the excess material and/or increases a stiffness of the plurality of additively manufactured objects
Implementation Method 3
an energy source configured to apply energy to the plurality of additively manufactured objects to selectively alter a material property of at least a portion of each additively manufactured object
Data Source
AI summary
Systems, methods, and devices for post-processing additively manufactured objects are disclosed herein. In some embodiments, a system includes a rotor configured to support a plurality of additively manufactured objects having excess material thereon. The system can further include an actuator configured to spin the rotor so as to remove the excess material from the plurality of additively manufactured objects. The system can further include a sensor configured to obtain sensor data indicative of a cleaning status of the plurality of additively manufactured objects while the plurality of additively manufactured objects remain on the rotor. The system can further include a controller configured to adjust, based on the sensor data, an operational parameter of the rotor that enhances removal of the excess material from the plurality of additively manufactured objects.