Additive Manufacturing Part Removal Using Vibration Fluidization
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Solution Overview
Problem
Current methods for unpacking components produced by additive manufacturing are labor-intensive, time-consuming, and require significant space and additional devices, leading to high costs and potential dust-related safety issues.
Innovation Solution
A method utilizing a rotatable and vertically/displacement removal device, potentially automated, that uses a vacuum system with a suction cup to gently lift components, combined with fluidization techniques like vibration or air flow to clean the component surfaces and retain particulate material within the construction box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional unpacking methods (suction, mechanical removal) are used, then non-solidified particulate material can be removed from components, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent applies mechanical vibration to the construction box or base plate to fluidize the non-solidified particulate material, enabling automatic removal without manual suction or mechanical cleaning. The vibration causes particles to move and separate from components, resolving the contradiction between ease of manufacture and productivity.
Solution Approach 2:
The system uses the inherent properties of the particulate material and vibration-induced fluidization to achieve self-cleaning of components. The material naturally flows and separates from components under vibration, eliminating the need for external suction devices or manual intervention, thus improving both ease of manufacture and productivity.
2Ease of manufacture
If traditional unpacking methods are used, then components can be freed from particulate material, but significant space and additional devices are required
Solution Approach 1:
The patent combines the unpacking function with the existing construction box and base plate structure. The base plate serves dual purposes as both the support during manufacturing and the vibration source during unpacking, eliminating the need for separate unpacking equipment and reducing device complexity while maintaining ease of manufacture.
Solution Approach 2:
The construction box and base plate are designed to perform multiple functions: manufacturing support, vibration generation, and material containment. This multi-functionality reduces the need for additional dedicated unpacking devices, resolving the contradiction between ease of manufacture and device complexity.
3Ease of manufacture
If suction methods are used for unpacking, then particulate material can be removed, but a great deal of work and time is required
Solution Approach 1:
The patent replaces time-consuming suction operations with rapid mechanical vibration that fluidizes and removes particulate material in seconds. The vibration-induced fluidization causes material to automatically flow away from components, dramatically reducing unpacking time while maintaining effective material removal.
Solution Approach 2:
The patent replaces the mechanical suction system with a vibration-based system. Instead of using suction forces to remove material, the system uses vibration to fluidize and redistribute particles, allowing gravity and flow to perform the removal function, thus reducing time and operational complexity.
4Ease of manufacture
If blowing methods are used to remove particulate material, then material can be displaced, but high levels of dust formation occur creating safety issues
Solution Approach 1:
The patent uses controlled mechanical vibration to fluidize and move particulate material in a contained manner. The vibration causes material to flow smoothly rather than being violently blown, significantly reducing dust formation and associated safety hazards while maintaining effective material removal capability.
Solution Approach 2:
The patent employs controlled air flow or fluidization through the particulate bed to move material gently. By using pneumatic fluidization rather than blowing, the system achieves material removal with minimal dust generation, as particles are suspended and moved through controlled pressure differentials rather than forced air streams.
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 significantly reduces the time and cost of unpacking, enhances operator safety, improves surface roughness, and minimizes the need for subsequent cleaning steps by effectively removing unwanted material while keeping the bulk of the particulate material within the construction box.
Implementation Method 1
at least one vacuum device is used as the removal device, which preferably contacts the at least one component from above by means of a suction cup
Implementation Method 2
the removal device can be designed in such a way to carry out movements, in particular periodic movements, in the vertical and/or horizontal direction or about a vertical and/or horizontal axis with the at least one component
Implementation Method 3
the unsolidified particulate material is fluidized and the at least one component is transported away from the construction box
Data Source
Figure 1~2
Figure 3a~3b
Figure 4~5a
AI summary
The disclosure relates to a method for unpacking at least one component (2), produced by means of an additive manufacturing process, from a particulate material bed of non-consolidated particulate material (3), wherein the non-consolidated particulate material (3) is arranged together with the at least one component (2) in a build box (1) that is open at the top in the vertical direction and delimited by an upper edge (6), and is delimited at the bottom by a base plate (4) and on the sides by a surrounding wall (5), wherein the non-consolidated particulate material (3) is fluidised and the at least one component (2) is transported by means of a transport device (8) from the build box (1), and wherein the non-consolidated particulate material (3) remains in the build box (1).