Additive Manufacturing Substrate Unit with Detachable Connecting Elements
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Solution Overview
Problem
In additive manufacturing, the separation of shaped bodies from substrate units is often manual, costly, and results in material waste and reduced automation options, as the substrate units are either damaged or require frequent replacement due to the need for material compatibility and complex separation processes.
Innovation Solution
A substrate unit system where the application surface does not form a material connection with the starting material, using detachable connecting elements made of a material suitable for the shaped body, allowing for easy detachment and reuse of the substrate unit, and enabling efficient further processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the application surface is made of material corresponding to the starting material to ensure good material connection, then the material bond between shaped body and substrate unit is improved, but the substrate unit cannot be reused and requires frequent replacement
Solution Approach 1:
The substrate unit is divided into two functional parts: a reusable base substrate unit and a consumable connecting element. The connecting element is made of material compatible with the starting material to ensure good material connection, while the base substrate unit can be reused for multiple production cycles. This segmentation resolves the contradiction by isolating the material compatibility requirement to only the connecting element portion.
Solution Approach 2:
The connecting element is designed as a disposable, low-cost component that is consumed during the separation process. By making only the connecting element disposable rather than the entire substrate unit, the system achieves both good material connection (through compatible material in the connecting element) and substrate unit reuse (since the base substrate unit remains intact).
2Productivity
If multiple shaped bodies are constructed on the same substrate unit to increase productivity, then production efficiency is improved, but the shaped bodies become inaccessible for further processing steps
Solution Approach 1:
The system segments the connection between shaped bodies and substrate unit through detachable connecting elements. These connecting elements can be selectively removed to provide access to the shaped bodies for further processing, while allowing multiple shaped bodies to remain on the substrate unit during the additive manufacturing process. This enables both high productivity and ease of operation.
Solution Approach 2:
The connecting elements provide a dynamic connection that can be changed from attached to detached state. During manufacturing, the connecting elements maintain the shaped bodies on the substrate unit for efficient batch production. When further processing is needed, the connecting elements can be detached to provide access, and the shaped bodies can be reattached later if needed. This dynamic capability resolves the contradiction between productivity and accessibility.
3Manufacturing precision
If manual separation is used to remove shaped bodies from substrate unit, then separation precision can be maintained, but time consumption and costs increase
Solution Approach 1:
The connecting elements are designed to enable self-service separation through the material bond between the connecting element and the shaped body. The separation process exploits the controlled weakness of the connecting element, allowing automatic or semi-automatic separation without requiring complex manual operations. This maintains separation precision while significantly reducing time consumption and costs.
Solution Approach 2:
The connecting element is designed as a consumable component that is easily separated and discarded. By making the connecting element disposable and inexpensive, the system enables rapid separation processes that do not require time-consuming manual operations. The low cost of the connecting element allows for automated separation methods that maintain precision while reducing time and labor costs.
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 approach reduces material waste, lowers costs, and enhances automation by allowing multiple shaped bodies to be produced on the same substrate unit, with reduced residual stresses and distortion in the final product.
Implementation Method 1
a powder of a starting material is applied in a defined thin layer to the application surface and is melted locally by means of an energy supply, e.g. in the form of a beam, for example by means of a laser, and connected to the application surface
Data Source
Figure 1~2
Figure 3~6
Figure 7~8
AI summary
A method for additive manufacturing in which a starting material is applied to an application surface (3) of a substrate unit (1), at least one portion of the starting material is hardened to form a molded body (20) and the molded body (20) is removed from the substrate unit (1), wherein, for the application surface (3), an application surface material is used which does not form an integrally bonded connection with the starting material during method step b) and, during the method step after feature b), an integrally bonded connection is created between the molded body (20) and at least one connection element (6) detachably provided on the substrate unit (1). Furthermore, a substrate unit system suitable for use in this method is provided.