WO2022231968A1

WO2022231968A1 - Method and system for finishing additively manufactured objects using a directed fluid spray against a reflection panel

Info

Publication number: WO2022231968A1
Application number: PCT/US2022/025929
Authority: WO
Inventors: Daniel Joshua HUTCHINSON
Original assignee: Postprocess Technologies, Inc.
Priority date: 2021-04-27
Filing date: 2022-04-22
Publication date: 2022-11-03

Abstract

An apparatus and method are disclosed for removing support material from additively manufactured parts or smoothing surfaces of additively manufactured parts. The apparatus includes a chamber having a component that positions the additively manufactured parts in the chamber. A chemical formulation is sprayed at the additively manufactured parts from below. The spray impacts a reflection panel located above the additively manufactured parts and is redirected downward onto the additively manufactured parts from above thereby removing support material from the additively manufactured parts or smoothing surfaces of the additively manufactured parts.

Description

METHOD AND SYSTEM FOR FINISHING ADDITIVELY MANUFACTURED OBJECTS USING A DIRECTED FLUID SPRAY AGAINST A REFLECTION PANEL

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of the filing date under 35 U.S.C. § 119(e) of U.S. Provisional Application Serial No. 63/180,315, filed April 27, 2021, the entirety of which is incorporated by reference herein and relied upon.

[0002] This patent application is related to US Ser. No. 17/088,174, filed November 3, 2020, which was a divisional of US Ser. No. 16/232,955, filed December 26, 2018, now US Pat. No. 10,850,449, which claimed priority to 62/612,483 filed December 31, 2017, the entire disclosures of which are hereby incorporated by reference.

FIELD OF THE INVENTION

[0003] This invention relates generally to an apparatus for removing support material from or smoothing surfaces of parts that have been made by additive manufacturing.

BACKGROUND OF THE INVENTION

[0004] Additive manufacturing processes (also referred to as 3D printing) enable the production of parts having complex geometries that would be difficult or impossible with traditional manufacturing techniques, such as casting, injection molding, or forging. Additive manufacturing processes also enable the production of parts quickly without extensive setup or tooling. Additive manufacturing processes include for example Selective Laser Sintering (SLS), Stereolithography (SLA), fused deposition modeling (FDM), material jetting (MJ), electron beam (e-beam), and others. One drawback is that some additive manufacturing processes produce parts that require removal of unwanted support material. The support material is needed with some additive manufacturing processes to support portions of the part as the part is being printed. After the additive manufacturing process is completed, the unwanted support material needs to be removed. The support material can have a complex geometry and can also be extensive.

[0005] Additionally, because additive manufacturing produces a part in layers, a surface of the part may be rough or striated because adjacent layers may not line up exactly during the printing process. Such a surface may be unappealing from a visual standpoint or may be incompatible with the ultimate application in which the part will be used. [0006] Prior approaches to address the need to remove support material from additively manufactured parts include manual approaches, such as using sandpaper or brushes, or machines, such as chemical baths or agitators. These prior approaches have drawbacks, such as being time-consuming, inefficient, inconsistent, and potentially damaging to the part. [0007] PostProcess Technologies, Inc., of Buffalo, NY, has developed several product lines of solutions to meet the need for removal of support material from additively manufactured parts and to smooth surfaces of additively manufactured parts. These solutions include the VORSA™, BASE™, and the DECI™ support removal solutions. These PostProcess® solutions remove support material from parts made by various additive manufacturing processes including FDM, SLA, CLIP, PolyJet, and more. These PostProcess® solutions use the PostProcess® Volumetric Velocity Dispersion (VVD) technology. The VVD technology includes high volume and flow streams of detergent spraying bidirectionally at the additively manufactured parts. These PostProcess® solutions remove support material in a consistent, efficient and high quality manner. However, there continues to be room for improvements.

SUMMARY OF THE INVENTION

[0008] The invention comprises an improved apparatus and method for removing support material from additively manufactured parts or smoothing surfaces of additively manufactured parts. The apparatus includes a chamber having a component, such as a platform, that positions the additively manufactured parts in the chamber. A chemical formulation is sprayed at the additively manufactured parts from below. The spray impacts a reflection panel located above the additively manufactured parts and is deflected downward onto the additively manufactured parts from above thereby removing support material from the additively manufactured parts or smoothing surfaces of the additively manufactured parts.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] For a fuller understanding of the nature and objects of the invention, reference should be made to the accompanying drawings and the subsequent description.

[0010] FIG. 1 is a diagram of an embodiment disclosed in US Pat. No. 10,850,449 of an apparatus for finishing additively manufactured objects.

[0011] FIG. 2 is a diagram of an apparatus for finishing additively manufactured objects in accordance with an embodiment of the present invention. [0012] FIG. 3 is a diagram of the embodiment of FIG. 2 at another stage of operation.

[0013] FIG. 4 is a side sectional view of an alternate embodiment of the chamber ceiling in FIGS. 2 and 3.

[0014] FIG. 5 is a side sectional view of another alternative embodiment of the chamber ceiling in FIGS. 2 and 3.

[0015] FIG. 6 is a side sectional view of yet another alternative embodiment of the chamber ceiling in FIGS. 2 and 3.

[0016] FIG. 7 is a side sectional view of still yet another alternative embodiment of the chamber ceiling in FIGS. 2 and 3.

[0017] FIG. 8 is a diagram showing an alternate embodiment of the motor mechanism for operation of the chamber ceiling in FIGS. 2 and 3.

[0018] FIG. 9 is a diagram showing another alternate embodiment of the motor mechanism for operation of the chamber ceiling in FIGS. 2 and 3.

[0019] FIG. 10 is a diagram showing still another alternate embodiment of the motor mechanism for operation of the chamber ceiling in FIGS. 2 and 3.

[0020] FIG. 11 is a diagram showing yet another alternate embodiment of the motor mechanism for operation of the chamber ceiling in FIGS. 2 and 3.

[0021] FIG. 12 is a diagram showing still yet another embodiment of the motor mechanism for operation of the chamber ceiling in FIGS. 2 and 3.

[0022] FIG. 13 is a diagram showing a further alternate embodiment of the motor mechanism for operation of the chamber ceiling in FIGS. 2 and 3.

[0023] FIG. 14 is a diagram of an apparatus for finishing additively manufactured objects in accordance with another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0024] Like drawing numbers on different drawing views identify identical, or functionally similar, structural elements of the invention.

[0025] Furthermore, it is understood that this invention is not limited to the particular methodology, materials, or modifications described and, as such, the invention may vary from that which is disclosed herein. It is also understood that the terminology used herein is for the purpose of describing particular aspects, and this invention is not limited to the disclosed aspects. [0026] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention pertains. It should be understood that methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the method and apparatus.

[0027] Furthermore, as used herein, "and/or" is intended to mean a grammatical conjunction used to indicate that one or more of the elements or conditions recited may be included or occur.

[0028] FIG. 1 shows a diagram of an apparatus 8 for surface finishing additively manufactured parts (also referred to herein as “objects”). FIG. 1 is a copy of FIG. 1 in US Pat. No. 10,850,449. The apparatus 8 uses a fluid formulation 22 (also referred to as a “chemical formulation” or a “detergent”) to remove support material from one or more additively manufactured parts or smooth a surface of one or more additively manufactured parts 10. Suitable fluid formulations are disclosed in WO 2020/006141, filed June 26, 2019, the entire disclosure of which is incorporated by reference herein. Suitable formulations include the following consumable products from PostProcess Technologies, Inc.: PLM-101- SPRAY, PLM- 102-SPRAY, PLM-201 -SPRAY, PLM-202-SPRAY, PLM-401 -SPRAY, and PLM-402-SPRAY,

[0029] The apparatus 8 includes a spraying chamber 16 (also referred to as a spray chamber). Located in the spraying chamber 16 is a platform 13. One or more additively manufactured parts 10 to be finished are located on the platform 13. Located in the spraying chamber 16 are a set of one or more bottom spray nozzles 25B and a set of one or more upper spray nozzles 25 A. The bottom spray nozzles 25B are located below the platform 13 and the upper spray nozzles 28B are located above the platform 13. The upper spray nozzles 28B are oriented vertically downward to spray at parts located on the platform 13 from above. The bottom spray nozzles 25B are oriented vertically upward to spray at parts located on the platform 13 from below. The platform 13 has openings (not shown) so that the fluid formulation 22 sprayed from the bottom spray nozzles 25B can pass through the platform 13 and impact on the parts 10 located thereupon. The openings in the platform 13 also allow the fluid formulation 22 sprayed at the parts 10 from the bottom spray nozzles 25B and the upper spray nozzles 25 A to fall through the platform 13 and not collect on a top surface of the platform 13. [0030] Located below the platform 13 is a tank 31. After being sprayed at the parts 10 on the platform 13, the fluid formulation 22 sprayed at the parts 10 passes through the openings in the platform 13 and falls into the tank 31.

[0031] A pump 33 is connected to the tank 31 by a suitable conduit. The pump 33 draws the fluid formulation 22 from the tank 31 and then pumps the fluid formulation 22 through piping 50 to the bottom spray nozzles 25B and the upper spray nozzles 25A causing the fluid formulation 22 to be sprayed at the parts 10 located on the platform 13. After being sprayed at the parts 10, the fluid formulation 22 collects back into the tank 31 from which it is pumped back again to the upper spray nozzles 25A and bottom spray nozzles 25B.

[0032] As stated above, the apparatus 8 is operated to finish additively manufactured parts, and more particularly to remove support material from additively manufactured parts or smooth surfaces of additively manufactured parts. US Pat. No. 10,850,449 includes further details and information about the apparatus 8 and its components and operation.

[0033] First embodiment

[0034] FIGS. 2 and 3 show a first embodiment of the present invention. FIGS. 2 and 3 show an apparatus 108 for finishing additively manufactured parts. Finishing additively manufactured parts includes removing support material from additively manufactured parts and/or smoothing surfaces of additively manufactured parts. The apparatus 108 is similar to the apparatus 8 in FIG. 1, except as described herein.

[0035] The apparatus 108 includes a spraying chamber 116. The chamber 116 contains air, although other gases may be suitable. In one embodiment, the air is the chamber is maintained below atmospheric pressure to facilitate ventilation and reduce leakage. An embodiment of a ventilation system that can be used with the apparatus is disclosed in PCT/US2021/063330, filed December 14, 2021, the entire disclosure of which is incorporated by reference herein.

[0036] Located in the spraying chamber 116 is a component for holding parts in position in the spraying chamber 116. In the embodiment in FIGS 2 and 3, this component is a platform 113. The platform 113 is sized for holding parts 110 made by additive manufacturing processes. The additively manufactured parts 110 require finishing (i.e., support material removal or surface smoothing). FIG. 2 shows the apparatus 108 at a stage of operation when the additively manufactured parts 110 to be finished have been placed on the platform 113 in the spraying chamber 116 of the apparatus 108, but the spraying process has not yet begun. [0037] Located in the spraying chamber 116 below the platform 113 is a set of one or more bottom spray nozzles 125B. The bottom spray nozzles 125B are operable to spray a fluid formulation 122 (shown in FIG. 3) at the parts 110 located on the platform 113. The fluid formulation 122 used in the apparatus 108 may be the same composition as the fluid formulation 22 described in connection with the apparatus 8 in FIG. 1. In the apparatus 108 in FIGS. 2 and 3, the bottom spray nozzles 125B can be formed and implemented as fluid outlets that direct the flow of fluid formulation outward up toward the platform 113. The bottom spray nozzles 125B are oriented vertically upward to spray at the parts 110 located on the platform 113 from below.

[0038] The platform 113 has openings 114 so that the fluid formulation 122 sprayed from the bottom spray nozzles 125B can pass through the platform 113 and impact on the parts 110 located thereupon. The openings 114 in the platform 113 also allow the fluid formulation 122 sprayed at the parts 110 from the bottom spray nozzles 25B to fall back down through the platform 113 after being sprayed at the parts 110 and not collect on a top surface of the platform 113.

[0039] Located below the platform 113 and below the bottom spray nozzles 125B is a tank 131. The tank 131 collects the fluid formulation 122 after it has been sprayed at the parts 110. A conduit 130 connects the tank 131 to apump 133. The pump 133 draws the fluid formulation 122 from the tank 131 and then pumps the fluid formulation 122 through piping 150 to the bottom spray nozzles 125B causing the fluid formulation 22 to be sprayed at the parts 10 located on the platform 113. After being sprayed at the parts 110, the fluid formulation 22 collects back into the tank 131 from which it is pumped back again to the nozzles 125B.

[0040] Compared to the apparatus 8 in FIG. 1, the apparatus 108 in FIGS. 2 and 3 does not have a set of upper spray nozzles.

[0041] The apparatus 108 in FIGS. 2 and 3 includes a reflection panel 170. The reflection panel 170 is located in the spraying chamber 116. The reflection panel 170 serves as an upper wall of the spraying chamber 116. The reflection panel 170 is located between an actual chamber ceiling 172 and the platform 113. The reflection panel 170 has dimensions such that it extends substantially across the spraying chamber 116 above the platform 113. [0042] Connected to an upper side of the reflection panel 170 is a shaft 174. The shaft 174 extends through an opening 176 in the actual chamber ceiling 172. The shaft 174 connects to a motor 178. The motor 178 is operable to move the shaft 174 and the reflection panel 170 connected thereto between an upper position, shown in FIG. 2, and a lower position, like the one shown in FIG. 3. There is sufficient clearance between the reflection panel 170 and the side walls of the spraying chamber 116 to allow the reflection panel 170 to move between the upper and lower positions. A sealing member (not shown) may be located around a perimeter of the reflection panel 170 or alternatively, no sealing member may be used. In order to facilitate exhaust ventilation in the chamber 116, the reflection panel 170 may be spaced from a wall of the spraying chamber 116 or may include one or more openings. Alternatively, an exhaust duct may be located adjacent to the platform 113.

[0043] FIG. 3 shows the apparatus 108 with the reflection panel 170 in a lower position. FIG. 3 also shows the apparatus 108 being operated to spray the fluid formulation 122 at the parts 110 on the platform 113. As shown in FIG. 3, some of the fluid formulation 122 being sprayed at the parts 110 from the bottom spray nozzles 125B impacts the parts 110 directly after passing through the openings 114 in the platform 113. Further as shown in FIG. 3, some of the fluid formulation 122 passes through the openings 114 in the platform 113 and impacts a lower side of the reflection panel 170. The fluid formulation 122 that passes through the openings 114 in the platform 113 and impacts the lower side of the reflection panel 170 splatters against and is redirected (i.e., deflected) by the reflection panel 170. Some of this redirected fluid formulation 122 then impacts and falls upon the parts 110 located on the platform 113 from above.

[0044] To operate the apparatus 108, the parts 110 to be finished are placed on the platform 113 with the reflection panel 170 in an upper, e.g., “loading”, position, as shown in FIG. 2. Having the reflection panel 170 in an upper position provides room for an operator to position the parts 110 in a suitable arrangement on the platform 113. After the parts 110 are positioned suitably on the platform 113, the position of the reflection panel 170 is adjusted so that it is closer to the platform 113, e.g., in an “operating” position. The motor 178 is operated to move the reflection panel 170 into a desired position. The motor 178 is operatively connected to a processing unit 1102 of the apparatus 108 so that it can be operated through a user interface 138. The distance of the reflection panel 170 relative to the platform 113 is adjustable and determined taking into account the size and geometry of the parts 110 to be finished that are located on the platform 113. Larger sized parts 110 may require more room above the platform 113 than smaller sized parts. Therefore, the reflection panel 170 may be moved to a position closer to the platform 113 for smaller sized parts than for larger sized parts. The height of the reflection panel 170 above the platform 113 is also determined to provide for enough space above the parts 113 to allow for the spray from the bottom spray nozzles 125B to impact the reflection panel 170 and splatter sufficiently to disperse and drench the parts 110 on the platform 113.

[0045] When the reflection panel 170 is set at an appropriate height, the chamber 116 is closed and the pump 133 operated to spray the parts 110 on the platform 113. The finishing process proceeds in a manner similar to the process disclosed in US Pat. No. 10,850,449. [0046] The embodiment 108 has several advantages. One advantage is that it provides for finishing parts made by additively manufacturing with a flow of finishing formulation that is comparable to the apparatus 8 in FIG. 1. Another advantage of the embodiment of the apparatus 108 is that it provides a suitable flow of finishing formulation with fewer spray nozzles. Another advantage of the embodiment of the apparatus 108 is that as the reflection panel is moved closer in position to the platform, the volume of the chamber 116 is reduced, thereby increasing the efficiency of the finishing process.

Alternative embodiments

[0047] In the embodiment of the apparatus 108 shown in FIGS. 2 and 3, the lower side of the reflection panel 170 is shown as being flat. The reflection panel 170, or surface of the lower side thereof, may have a shape, profile, surface features or texture that modifies or enhances dispersion or redirection of the spray impacting upon it. FIGS. 4-7 show alternative embodiments of the surface of the lower side of the reflection panel 170. In FIG. 4, a lower side 270 of the reflection panel 170 has a cupped surface, formed of a plurality of down ward facing curves or spherical depressions. In FIG. 5, a lower side 272 of the reflection panel 170 has a ridged surface, formed of a plurality of downward-facing angled ridges. In FIG. 6, a lower side 274 of the reflection panel 170 has a faceted surface, formed with a plurality of downward-facing triangular or conical shapes. In FIG. 7, a lower side 276 of the reflection panel 170 has an overall curved shape. The embodiments in FIGS. 2-7 showing different shapes or textures of the lower surface of the reflection panel 170 are not the only shapes or textures that can be used and various other shapes and textures may be used, including dimpled, ridged, cupped, pocked, faceted, and bowed. Additionally, two or more different shapes or textures may be combined. For example, the cupped surface shown in FIG. 4 may be combined with an overall curved surface like the one shown in FIG. 7. In a further embodiment, the shape of the reflection panel can be changeable or dynamic, i.e., capable of being modified in shape in order to adapt to finishing different sizes and types of additively manufactured objects, or capable of being modified in shape during a finishing process in order to modify the redirected spray as support material is removed or a surface is smoothed. The shape of the reflection panel can be selected or modified to focus the redirected spray at a specific location on the parts or platform.

[0048] In one embodiment, the reflection panel 170 remains stationary after it is moved into position close to the platform 113 and while the parts 110 are being sprayed. In alternative embodiments, the reflection panel 170 may be caused to move during spraying. The reflection panel 170 may be moved to enhance dispersion of the fluid spray impacting thereupon. FIGS. 8-13 show embodiments in which the reflection panel 170 is moved with different movements to enhance dispersion of the fluid spray impacting thereupon. The different types of movements may be implemented by the motor 128 under the control of the central processing unit 1102, shown in FIGS. 2 and 3. It will be appreciated that the disclosed different types of movements may be implemented in combination with the disclosed reflection panels having different shapes, textures or surface profiles to achieve a desired dispersion or redirection effect.

[0049] FIG. 8 shows an embodiment in which the motor 178 causes the shaft 174 to move with a circular stirring motion. FIG. 9 shows an embodiment in which the motor 178 causes the shaft 174 to oscillate back-and-forth rotationally about its vertical axis. FIG. 10 shows an embodiment in which the motor 178 causes the shaft 174 to move with a single axis horizontal left-and-right motion. FIG. 11 shows an embodiment in which the motor 178 causes the shaft 174 to move with a two-axis horizontal motion, i.e., left-and-right and backward-and-forward. FIG. 12 shows an embodiment in which the motor 178 causes the shaft 174 to move with a rocking pivoting motion. FIG. 13 shows an embodiment in which the motor 178 causes the shaft 174 to move, e.g., vibrate, with an up-and-down, oscillating motion. Other movements may also be used, such as a wobbling movement.

[0050] The movements shown in FIGS. 8-13 may be continuous during the spraying process. Alternatively, the movements may be intermittent or cyclical. In further embodiments, multiple movements may be used during a finishing operation. Multiple movements may be implemented at the same time, or may be implemented sequentially or alternately.

[0051] FIG. 14 shows another alternative embodiment for finishing additively manufactured parts. FIG. 14 shows an apparatus 308. The apparatus 308 in FIG. 14 is similar to the apparatus 108 in FIGS. 2 and 3, except as explained herein. The apparatus 308 includes a spraying chamber 316 in which is located a height-adjustable platform 313. A motor 378 is operable to raise and lower the height-adjustable platform 313. In this embodiment, the height-adjustable platform 313 includes a shaft 374 that extends through an opening 376 in a top wall 372 of the chamber 316. The motor 378 is operably connected to the shaft 374 to move the height-adjustable platform 313 up and down. The motor 378 is operatively connected to a processing unit 3102 of the apparatus 308 so that it can be operated through a user interface 338. Parts 310 to be finished are positioned on the height- adjustable platform 313, e.g., when it is in a lower position. Then, the height-adjustable platform 313 is moved into an upper position in proximity to the top wall 372 of the chamber 316. The pump 333 is operated to cause a set of bottom spray nozzles 325B to spray a fluid formulation 322 through openings 314 in the height-adjustable platform 313 at the parts 310 located on the height-adjustable platform 313. The height-adjustable platform 313 positions the parts 310 located thereupon close to the top wall 372 of the chamber 316 where spray 322 from the bottom spray nozzles 325B impacts the top wall 372 of chamber 316, splatters, and falls onto the parts 310. This embodiment of the apparatus 308 differs from the embodiment of the apparatus 108 in FIGS. 2 and 3 in that instead of having a reflection panel that moves into position in proximity to parts located on a platform, the apparatus 308 has a height- adjustable platform 313 that moves parts located thereupon into proximity with the chamber ceiling, which functions similarly to the reflection panel and which may be shaped accordingly.

[0052] In the embodiment in FIG. 14, the bottom spray nozzles 325B are stationary. Alternatively, the bottom spray nozzles 325B can move together with the height-adjustable platform 313.

[0053] A further embodiment includes both a height-adjustable reflection panel, like the embodiment of the apparatus 108 in FIGS. 2 and 3, and a height-adjustable parts platform, like in the embodiment of the apparatus 308 in FIG. 14.

[0054] In some embodiments disclosed above, the motor that operated the reflection panel was described as being outside the chamber. In an alternative embodiment, the motor that operates the reflection panel can be located inside the chamber.

[0055] The embodiments disclosed herein were described as having bottom spray nozzles located below the platform in the spraying chamber that could be implemented as fluid outlets that direct the flow of fluid formulation toward the parts located on the platform. The bottom spray nozzles may increase the flow velocity or may modify the flow direction.

[0056] In an alternative embodiment, the reflection panel is not height-adjustable in relation to the platform. According to this alternative, the reflection panel is designed to have a specific non-adjustable height sufficiently close to the platform so that spray of fluid formulation from spray nozzles located below the platform and passing through the platform impact upon the reflection panel, splatter, and fall downward onto parts located on the platform.

[0057] In embodiments described above, the reflection panel or the height-adjustable platform were described as being connected to a motor, i.e., motor 178 or 378, to enable adjustment of height. In an alternative embodiment, the reflection panel or the height- adjustable platform may be adjustable via a mechanical movement mechanism such as a spring or counterweight, or via a mechanical attachment with a door to the chamber which actuates the movement of the reflection panel or the height-adjustable platform when opened and closed, or the reflection panel or the height-adjustable platform may be adjustable manually. In an alternative embodiment, the movement of the reflection panel or the height- adjustable platform may be automated such as via a sensor and controller which detects the height of the parts on the platform and automatically moves the reflection panel or the height- adjustable platform into an operating positions, e.g., to an optimal operating position.

[0058] In another alternative embodiment, instead of having a platform in a spraying chamber upon which the additively manufactured parts are placed, the additively manufactured parts can be held or fixed in position in the spraying chamber by other means, such as by wires or rods that extend horizontally and/or vertically, netting, or within a basket. [0059] A system like the one described herein can be used in equipment or systems that finish or otherwise process parts produced by other than additive manufacturing processes. For example, a system like the one described herein can be used in systems or equipment that finish or otherwise process parts produced by traditional manufacturing processes or other kinds of non-traditional manufacturing processes.

[0060] In the foregoing description, example embodiments are described. The specification and drawings are accordingly to be regarded in an illustrative rather than a restrictive sense.

[0061] It will be appreciated that various aspects of the above-disclosed invention and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, and/or improvements therein may be subsequently made by those skilled in the art, and those alternatives, modifications, variations, and/or improvements are intended to be encompassed by the following claims.

[0062] Although the present invention has been described with respect to one or more particular embodiments, it will be understood that other embodiments of the present invention may be made without departing from the spirit and scope of the present invention. Hence, the present invention is deemed limited only by the appended claims and the reasonable interpretation thereof.

Claims

CLAIMS:

1. A method of finishing an additively manufactured object comprising: spraying a fluid formulation upward against a reflection panel so that the fluid formulation is redirected downward onto an additively manufactured object positioned in a chamber; and collecting the fluid formulation after the fluid formulation has been redirected onto the additively manufactured object.

2. The method of Claim 1 wherein the additively manufactured object is fixed in position on a platform located in the chamber.

3. The method of Claim 2 wherein the spraying further comprises spraying the fluid formulation upward through openings in the platform wherein at least some of the fluid formulation impacts the additively manufactured object located on the platform from below.

4. The method of Claim 2 further comprising: elevating the platform into proximity of the reflection panel.

5. The method of Claim 2 further comprising: lowering the reflection panel into proximity of the platform.

6. The method of Claim 2 further comprising: before spraying, adjusting a distance of the reflection panel above the platform.

7. The method of Claim 1 further comprising: imparting movement to the reflection panel while spraying.

8. The method of Claim 7 wherein the movement comprises at least one of a circular stirring motion, an oscillating back-and-forth rotational motion, a single axis horizontal left-and-right motion, a two-axis horizontal motion, a rocking pivoting motion, and an up-and-down, oscillating motion.

9. The method of Claim 1 further comprising: after collecting the fluid formulation, pumping the collected fluid formulation to spray upward against the reflection panel again.

10. The method of Claim 1 wherein the finishing an additively manufactured object comprises at least one of removing support material from the additively manufactured object and smoothing a surface of the additively manufactured object.

11. An apparatus for finishing an additively manufactured object comprising: a spray chamber; a component located in the spray chamber that fixes a position of the additively manufactured object in the spray chamber; one or more fluid outlets located in the spray chamber below the position of the additively manufactured object in the spray chamber and oriented to direct a spray of a fluid formulation upward; and a reflection panel located above the position of the additively manufactured object in the spray chamber, wherein the reflection panel is located in sufficient proximity to the position of the additively manufactured object in the spray chamber so that the fluid formulation being sprayed upward impacts upon the reflection panel causing the fluid formulation to be redirected downward onto the additively manufactured object.

12. The apparatus of Claim 11 wherein the reflection panel is height-adjustable relative to the component that fixes the position of the additively manufactured object in the spray chamber.

13. The apparatus of Claim 11 wherein a bottom side of the reflection panel has a texture, feature, or shape to facilitate redirecting of the fluid formulation.

14. The apparatus of Claim 11 wherein the component that fixes the position of the additively manufactured object in the spray chamber is height-adjustable relative to the reflection panel.

15. The apparatus of Claim 11 further comprising: a motor operable connected to the reflection panel to impart movement thereto.

16. The apparatus of Claim 11 further comprising: a motor operable connected to the reflection panel to impart movement thereto during operation of the fluid outlets to spray fluid formulation, wherein said movement enhances redirection of the fluid formulation from the reflection panel.

17. The apparatus of Claim 11 further comprising: a tank located below the component that fixes the position of the additively manufactured object in the spray chamber operable to receive the fluid formulation after the fluid formulation is sprayed at the additively manufactured object.

18. The apparatus of Claim 17 further comprising: a pump connected to the tank and operable to pump the fluid formulation received in the tank to the one or more fluid outlets.

19. The apparatus of Claim 11 wherein said component that fixes the position of the additively manufactured object in the spray chamber comprises a platform that has at least one opening therein that allows passage of fluid formulation therethrough.

20. A method of finishing an additively manufactured object comprising: placing the additively manufactured object in a spray chamber on a component that fixes a position of the additively manufactured object in the spray chamber; moving a reflection panel into position in proximity to the additively manufactured object; and spraying a fluid formulation upward from spray nozzles located below the additively manufactured object to impact upon the additively manufactured object from below as well as impact against the reflection panel to be redirected down upon the additively manufactured object from above.

21. The method of Claim 20 further comprising: collecting the fluid formulation in a tank located below the additively manufactured object; and pumping the fluid formulation to the spray nozzles to spray at the additively manufactured object again.