Sequential Solvent Washing for Additive Parts
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Solution Overview
Problem
Conventional washing methods for additively fabricated parts, such as those produced through stereolithography, often leave residual uncured resin on the surface, which can affect the quality and finish of the parts, and existing solutions like solvent exposure may not be efficient in removing all residues effectively.
Innovation Solution
A washing apparatus and method utilizing a vessel with multiple solvent containers and controlled pumps and valves to perform sequential wash cycles with different solvents, including isopropyl alcohol and water, to effectively remove uncured resin from additively fabricated parts, with the option for agitation and circulation to enhance cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional solvent washing is used to remove uncured resin, then some resin removal is achieved, but residual resin remains on part surfaces affecting quality and surface finish
Solution Approach 1:
The washing process is divided into multiple sequential stages using different solvents (e.g., polar solvent like isopropyl alcohol followed by non-polar solvent like hexane). Each stage targets specific types of resin residues, with the first stage removing loosely bound resin and the second stage removing more tenaciously bound residues, thereby achieving complete removal that cannot be achieved with a single solvent.
Solution Approach 2:
The patent changes the chemical parameters of the washing process by sequentially changing solvent polarity and composition. The system transitions from polar to non-polar solvents, altering the chemical interaction mechanism with the resin at each stage to progressively remove different fractions of uncured material, ultimately achieving complete surface cleanliness.
2Productivity
If manual washing methods are used, then some cleaning can be performed, but manual handling of parts is required which reduces productivity and increases labor costs
Solution Approach 1:
The washing system is designed to automatically process parts without manual intervention. Parts are placed in a container that is automatically subjected to sequential solvent washing cycles through pump-driven circulation systems. The entire washing process, including solvent delivery, circulation, and drainage, operates autonomously, eliminating manual handling while maintaining effective cleaning.
Solution Approach 2:
The patent replaces manual mechanical washing actions with an automated fluid circulation system. Pumps automatically deliver solvents through controlled flow paths, and the system uses fluid dynamics rather than mechanical contact to achieve cleaning, thereby eliminating the need for manual part handling and increasing productivity.
3Manufacturing precision
If single solvent washing is used, then the process is simple and quick, but it cannot effectively remove all types of resin residues
Solution Approach 1:
The washing process is divided into multiple sequential stages using different solvents (e.g., polar solvent like isopropyl alcohol followed by non-polar solvent like hexane). Each stage targets specific types of resin residues, with the first stage removing loosely bound resin and the second stage removing more tenaciously bound residues, thereby achieving complete removal that cannot be achieved with a single solvent.
Solution Approach 2:
The patent changes the chemical parameters of the washing process by sequentially changing solvent polarity and composition. The system transitions from polar to non-polar solvents, altering the chemical interaction mechanism with the resin at each stage to progressively remove different fractions of uncured material, ultimately achieving complete surface cleanliness.
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 apparatus and method provide a comprehensive solution for removing residual resin, improving the surface finish and quality of additively fabricated parts by using sequential solvent washes and agitation, ensuring thorough cleaning without manual handling of the parts.
Implementation Method 1
a pump coupled to the first storage container and the second storage container, wherein the pump is coupled to the first valve and wherein the pump is located outside of the vessel and the pump is coupled to the one or more inlets of the vessel
Implementation Method 2
Conventional washing steps typically involve exposing the part to a solvent (e.g., isopropyl alcohol (IPA)) to remove the uncured resin
Data Source
AI summary
Washing apparatus and methods used to process additively fabricated (e.g., 3D printed) parts are described herein. The apparatus and methods may be used to wash uncured liquid resin from the parts.