Sacrificial Build Plate for Additive Manufacturing Separation

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Solution Overview

Problem

Conventional methods for separating 3D printed articles from build plates in liquid metal jet printing systems often damage the articles, particularly due to violent thermal contraction or fracturing, which can damage complex features and shorten the build plate's lifetime.

Innovation Solution

A build plate design featuring a sacrificial plate with a higher etch rate than the base, allowing for the sacrificial plate to be easily separated from the base using an etchant, thereby preventing damage to the 3D printed article. The sacrificial plate is coupled with the base through protuberances, mechanical fasteners, or electroplating, and can be separated before or during etching to release the article.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conventional separation methods (fracturing or sawing) are used to separate the article from the build plate, then the article can be removed, but complex and delicate features of the article are damaged

Engineering Contradiction:

Improvearticle separationVSAvoidarticle feature integrity

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The build plate is segmented into two distinct components: a reusable base and a sacrificial plate. The sacrificial plate is designed to be selectively removed through etching, while the base remains intact. This segmentation allows the article to be separated from the build plate without applying mechanical stress that would damage delicate features, as the sacrificial plate acts as a temporary carrier that can be chemically dissolved.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sacrificial plate serves as an intermediary between the article and the reusable base. It provides a temporary bonding surface during the printing process, then allows for clean separation through etching. This intermediary layer protects the article from direct contact with the base during separation, eliminating the need for violent fracturing or sawing operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If quenching in cold water is used to separate the article and build plate, then separation may be achieved through thermal contraction mismatch, but the process is violent and may damage the article and shorten build plate lifetime

Engineering Contradiction:

Improvearticle separationVSAvoidbuild plate lifetime

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The mechanical separation process (violent fracturing, sawing, or thermal shock) is replaced with a chemical process. The sacrificial plate is designed with selective etchability, allowing it to be removed through chemical etching rather than mechanical force. This substitution eliminates the violent stresses that would damage the article and extend the reusable base's operational life.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The separation mechanism changes from mechanical/thermal parameters to chemical parameters. Instead of relying on thermal contraction mismatch through quenching, the system uses differential etch rates between the sacrificial plate and the base materials. This parameter change allows for controlled, gentle separation that preserves both the article and the reusable base.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If a sacrificial plate with high etch rate is used, then easy separation from the base is achieved, but additional materials and processes are required

Engineering Contradiction:

Improvesacrificial plate separationVSAvoidbuild plate structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The build plate is divided into functional segments with distinct properties: a reusable base and a sacrificial plate. This segmentation enables the sacrificial portion to be optimized for easy chemical removal while the base maintains structural integrity. The modular design, though adding initial complexity, simplifies the overall process by enabling straightforward separation without affecting the base for future use.

Inventive Principle:

Principle #1Segmentation

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 enables the safe and efficient separation of 3D printed articles from build plates without damaging the articles, extending the build plate's lifetime by avoiding violent separation methods and preserving delicate features.

Implementation Method 1

The etch rate of the sacrificial plate in an etchant may be greater than an etch rate of the base in the etchant

Methodology Applied

Scientific EffectChemical etching: Chemical Beam Epitaxy

Implementation Method 2

The sacrificial plate may be coupled with the base via electroplating

Methodology Applied

Scientific EffectElectroplating: Electroplating

Data Source

PatentUS11738393B2Build plates for additive manufacturing systems and methods for the same

Publication Date: 2023.08.29 XEROX CORP

AI summary

A build plate for an additive manufacturing device and methods for the same are provided. The build plate may include a base and a sacrificial plate coupled with the base. The etch rate of the sacrificial plate in an etchant may be greater than an etch rate of the base in the etchant. A method for separating a 3D printed article supported on the build plate may include contacting the sacrificial plate with the etchant.