Additive Manufacturing Support Frame for Batch Handling
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Solution Overview
Problem
In additive manufacturing, particularly in powder bed and binder jetting processes, handling and post-processing of large batches of products with varying geometries and custom designs are inefficient due to lack of uniformity, increased risk of damage, and insufficient structural support, leading to complications and cost escalation.
Innovation Solution
A support frame system comprising interconnected struts and runners that surround and support objects after manufacturing, allowing for secure handling and post-processing, with optional spring runners for accommodating material shrinkage and a fixture point for easy handling and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large batches of products are manufactured using PBAM or BJAM, then productivity is improved, but handling complexity and damage risk increase
Solution Approach 1:
Multiple individual products are merged onto a single support frame to form a batch unit. The support frame acts as a carrier that holds multiple products together, allowing them to be handled as one unit during post-processing operations. This reduces the number of separate handling operations required and minimizes damage risk to individual products.
Solution Approach 2:
The support frame serves as an intermediary structure between the manufactured products and the post-processing equipment/operator. It provides a stable platform for handling fragile products during transport and processing, eliminating the need for direct manual handling of the products themselves and thereby reducing damage risk.
2Strength
If external supports are attached to the build plate during manufacturing, then structural support is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The support structure is merged with the build plate itself rather than being a separate attachable component. The build plate is designed with integrated support features that are formed as part of the manufacturing process, eliminating the need for separate support attachments and reducing manufacturing complexity.
Solution Approach 2:
The build plate provides its own structural support functions without requiring external support structures. The support features are built into the build plate design, allowing it to self-support the products during manufacturing and post-processing without additional complexity.
3Ease of manufacture
If products are handled during post-processing in a weakened state, then processing can be performed, but damage risk increases
Solution Approach 1:
The support frame acts as a protective intermediary that承载s the fragile products during post-processing operations. It provides mechanical support that compensates for the weakened state of the products, allowing handling and processing to occur without direct contact with the fragile product surfaces, thereby reducing damage risk.
Solution Approach 2:
The support frame is positioned beforehand to provide protective cushioning and support during post-processing operations. It anticipates the vulnerability of the products in their weakened state and provides pre-positioned support structures that prevent damage before handling occurs.
Data Source
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AI summary
A system for supporting an object created by additive manufacturing comprising the object, and a frame comprising at least one strut having a length and forming a shape at least partially surrounding the object, a runner having first and second ends, the first end integrally connected to a strut and the second end removably attached to the object.