Soluble Support Removal Apparatus with Flow Control
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Solution Overview
Problem
Conventional methods for removing water soluble support material from rapid prototype parts, such as those produced by Fused Deposition Modeling (FDM), are often costly, environmentally inappropriate, and pose health risks, particularly in office settings where they are not suitable for maintaining a clean environment.
Innovation Solution
A dedicated apparatus comprising a retention tank with a heating and agitation system, a pump, and a flow control subsystem, using an aqueous cleaning solution of sodium or potassium hydroxide and carbonate, to efficiently remove water soluble support material from rapid prototype parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional immersion parts washer is used to remove support material, then removal capability is improved, but cost and environmental appropriateness deteriorate
Solution Approach 1:
The patent uses disposable absorbent pads instead of expensive conventional immersion parts washers. The pads are inexpensive, single-use items that can be discarded after removing support material, eliminating the need for costly equipment while maintaining effective removal capability.
Solution Approach 2:
The patent extracts the support material removal function from the conventional immersion parts washer system and implements it through a simpler, dedicated apparatus using absorbent pads and solvents, separating this specific function from the general-purpose washing equipment.
2Reliability
If conventional immersion parts washer with ultrasonics is used, then cleansing action is improved, but health risks and environmental appropriateness deteriorate
Solution Approach 1:
The patent replaces the ultrasonic mechanical system with a chemical-mechanical system using solvents and manual rubbing with absorbent pads. This substitution eliminates ultrasonic health risks while maintaining effective cleansing action through chemical dissolution and mechanical absorption.
Solution Approach 2:
The patent introduces absorbent pads as an intermediary between the solvent and the support material. The pads absorb the dissolved support material and facilitate easy removal, mediating the cleansing process without requiring ultrasonic equipment.
3Ease of manufacture
If manual brushing is used to remove support material, then equipment cost is reduced, but time required and labor intensity increase
Solution Approach 1:
The patent uses absorbent pads that replicate and enhance the function of manual brushing. The pads are pre-formed with a structure that facilitates efficient absorption and removal, providing a improved version of the simple manual method without requiring complex equipment.
4Reliability
If repeated manual immersion is used, then support material removal is achieved, but time required and productivity deteriorate
Solution Approach 1:
The patent applies solvent to the absorbent pad before contacting the support material, performing preliminary chemical preparation. This pre-saturation with solvent enhances the pad's immediate dissolution and absorption capability, reducing the time required for removal and improving productivity.
Solution Approach 2:
The patent enables continuous removal action by using absorbent pads that maintain consistent contact with the support material surface. The pads continuously absorb dissolved material as they are rubbed across the surface, providing uninterrupted removal action that improves throughput compared to intermittent manual methods.
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 effectively removes water soluble support material from rapid prototype parts in an office setting, reducing the time required from several hours to approximately 30 minutes, enhancing throughput and ensuring a safe, clean environment.
Implementation Method 1
removing water soluble support material from the rapid prototype part
Implementation Method 2
a retention tank with a heating and agitation system
Implementation Method 3
a retention tank with a heating and agitation system
Data Source
AI summary
A system for removing soluble support material from a prototype part may include a container for receiving the prototype part. A pump may be in fluid communication with the container and may be configured to pump a solution into the container and out of the container. A flow control subsystem may control a rate of flow of the solution into the container and out of the container.