US20170348910A1 - Apparatus and method for support removal - Google Patents

Apparatus and method for support removal Download PDF

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Publication number
US20170348910A1
US20170348910A1 US15/611,435 US201715611435A US2017348910A1 US 20170348910 A1 US20170348910 A1 US 20170348910A1 US 201715611435 A US201715611435 A US 201715611435A US 2017348910 A1 US2017348910 A1 US 2017348910A1
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United States
Prior art keywords
tank
liquid mass
output
input
output tank
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
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US15/611,435
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English (en)
Inventor
Daniel Joshua Hutchinson
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PostProcess Technologies Inc
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Daniel Joshua Hutchinson
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to PCT/US2017/035500 priority Critical patent/WO2017210460A1/en
Priority to DE112017002807.8T priority patent/DE112017002807T5/de
Priority to GB1900079.3A priority patent/GB2566404B/en
Priority to KR1020187034758A priority patent/KR102398373B1/ko
Priority to GB2204053.9A priority patent/GB2601980B/en
Priority to GB2115471.1A priority patent/GB2597397B/en
Priority to JP2018562222A priority patent/JP7000354B2/ja
Priority to US15/611,435 priority patent/US20170348910A1/en
Application filed by Daniel Joshua Hutchinson filed Critical Daniel Joshua Hutchinson
Priority to ES201890076A priority patent/ES2711981B2/es
Publication of US20170348910A1 publication Critical patent/US20170348910A1/en
Assigned to POSTPROCESS TECHNOLOGIES, INC. reassignment POSTPROCESS TECHNOLOGIES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HUTCHINSON, Daniel Joshua
Priority to US16/519,237 priority patent/US10737440B2/en
Priority to US16/931,338 priority patent/US20200391436A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
    • B08B3/02—Cleaning by the force of jets or sprays
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/188—Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
    • B08B3/006—Cabinets or cupboards specially adapted for cleaning articles by hand
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
    • B08B3/04—Cleaning involving contact with liquid
    • B08B3/08—Cleaning involving contact with liquid the liquid having chemical or dissolving effect
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
    • B08B3/04—Cleaning involving contact with liquid
    • B08B3/10—Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
    • B08B3/04—Cleaning involving contact with liquid
    • B08B3/10—Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration
    • B08B3/102—Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration with means for agitating the liquid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
    • B08B3/04—Cleaning involving contact with liquid
    • B08B3/10—Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration
    • B08B3/12—Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration by sonic or ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B7/00—Cleaning by methods not provided for in a single other subclass or a single group in this subclass
    • B08B7/0014—Cleaning by methods not provided for in a single other subclass or a single group in this subclass by incorporation in a layer which is removed with the contaminants
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B7/00—Cleaning by methods not provided for in a single other subclass or a single group in this subclass
    • B08B7/0064—Cleaning by methods not provided for in a single other subclass or a single group in this subclass by temperature changes
    • B08B7/0071—Cleaning by methods not provided for in a single other subclass or a single group in this subclass by temperature changes by heating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/35—Cleaning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/40—Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23G—CLEANING OR DE-GREASING OF METALLIC MATERIAL BY CHEMICAL METHODS OTHER THAN ELECTROLYSIS
    • C23G5/00—Cleaning or de-greasing metallic material by other methods; Apparatus for cleaning or de-greasing metallic material with organic solvents
    • C23G5/02—Cleaning or de-greasing metallic material by other methods; Apparatus for cleaning or de-greasing metallic material with organic solvents using organic solvents
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23G—CLEANING OR DE-GREASING OF METALLIC MATERIAL BY CHEMICAL METHODS OTHER THAN ELECTROLYSIS
    • C23G5/00—Cleaning or de-greasing metallic material by other methods; Apparatus for cleaning or de-greasing metallic material with organic solvents
    • C23G5/02—Cleaning or de-greasing metallic material by other methods; Apparatus for cleaning or de-greasing metallic material with organic solvents using organic solvents
    • C23G5/04—Apparatus
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23G—CLEANING OR DE-GREASING OF METALLIC MATERIAL BY CHEMICAL METHODS OTHER THAN ELECTROLYSIS
    • C23G5/00—Cleaning or de-greasing metallic material by other methods; Apparatus for cleaning or de-greasing metallic material with organic solvents
    • C23G5/06—Cleaning or de-greasing metallic material by other methods; Apparatus for cleaning or de-greasing metallic material with organic solvents using emulsions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B2203/00—Details of cleaning machines or methods involving the use or presence of liquid or steam
    • B08B2203/007—Heating the liquid

Definitions

  • the present disclosure pertains generally to an apparatus and method for removing support material from a part formed by three-dimensional printing.
  • Various systems exist for removing support material from a 3D printed part These systems often relate to methods for agitating a 3D printed part in a liquid media designed to erode support material surrounding the part. Additional known methods of support removal for three dimensional objects include raising and lowering temperature in a support removal tank to melt the support material, where the support material has a lower melting point than the part.
  • Known systems may utilize a single tank into which the raw part is submerged, or they may include multiple tanks having different properties, including differing temperature or liquids.
  • U.S. Pat. No. 8,636,850 to Narovlyansky discloses a method for removing the support structures from 3D objects using a liquid jet.
  • the '850 process generally involves inserting two or more objects made by solid freeform fabrication into a cell having an inlet to receive a high-pressure liquid jet located at a top side of the cell and a plurality of draining perforations at the circumferential wall of the cell.
  • U.S. Pat. No. 8,459,280 to Swanson discloses a support structure removal system comprising a reservoir tank and base unit.
  • the vessel comprises a vessel body, a porous floor configured to retain a 3D part, and an impeller rotatably mounted below the porous floor.
  • the impeller is rotated under magnetic force to agitate the solution around the part.
  • the tank may have a means for adjusting pH and temperature to promote support removal.
  • U.S. Pat. No. 7,546,841 to Tafoya discloses a device for support removal using liquid agitation and heat in a tank. Communication between a thermocouple in the tank and a microprocessor monitors the temperature in the tank and adjusts conditions accordingly.
  • the above systems often require manual adjustment throughout the process to adjust for various parts.
  • the above systems may be optimally designed for certain types of parts, and may work well for parts of known and tested sizes, shapes and materials.
  • much adjustment in setting parameters such as heat, pH, and time is required on the part of the operator to optimize efficient use of energy and time.
  • the drawbacks of the current support removal systems include a lack of efficiency when used for a wide variety of parts. Further, movement of the center of mass of the part throughout the tank increases inefficiency and provides an opportunity for delicate parts to collide with the walls of the tank or components of the machine. Such collisions may cause the part to fracture, and also increase inefficiency through uncontrolled movement within the tank.
  • Efficient support removal for a wide variety of materials and part shapes and sizes requires a system that is responsive to changes in the part and the working environment surrounding the part. Further, a system is desired that can measure the parameters of the part, either directly or indirectly, and adjust automatically to unique properties of each part. Therefore, a need exists for a support removal machine that can efficiently handle the wide and expanding variety of part types encountered in the fast-growing field of three dimensional printing.
  • a solution to the problems of existing support removal devices is provided through a machine design that maximizes energy efficiency.
  • the present disclosure describes a support removal machine that responds automatically to changing conditions within a tank and structural changes in the part while maintaining the part in optimal location within the tank for support removal.
  • the continuous regulation of part motion and tank parameters through a novel combination of liquid flow, heat, ultrasonic radiation, and measurement capabilities, maximizes the use of energy and minimizes damage to the part.
  • a key functional feature of the present disclosure is the ability to maintain the position of the part in a generally central location in the tank. This is accomplished through the use of manifolds positioned at specific locations throughout the tank to create a rotational liquid flow that creates liquid current that sinks parts that would otherwise float and floats parts that would otherwise sink. Under these rotational flow conditions, parts are centrally located submerged in the tank and rotate along with the flow of the liquid.
  • one or more manifolds may be located at the bottom of the tank along with one on the weir wall. The locations of the pump connected to the manifolds allows for the use of commercially available pumps, rather than custom built pumps, because the manifolds were designed around the pumps.
  • Rotation of the part within the liquid mass creates friction between the materials in the liquid mass and the part, thereby causing support removal.
  • Support removal is enhanced by ultrasonic transducers placed tangentially in the tank to the rotating object.
  • the ultrasonic generators create heat within the designated liquid mass within the tank, which enhances support removal, while also causing cavitation through direct interaction with the rotating part.
  • the part generally circulates around a central point in a tank, and the part itself rotates. The motion of the part in the tank creates a controlled agitation. As the part spins and circulates within the mass, each aspect of the part is exposed to the ultrasonic waves, thereby creating a synergistic effect in support removal through the circulatory and rotational effects of part motion and the ultrasonic enhancement of support destruction.
  • the ultrasonic interrogation of the part creates heat and cavitation in a generally uniform manner across the part.
  • a heating unit in the tank is also used to generate heat for support removal.
  • the heating unit and the ultrasonic generator operate in harmony, such that when the ultrasonic generator needs to be dialed down, the heater can compensate by maintaining the heat of the mass at an optimal level.
  • the part material is energy sensitive to deformation or delaminating so the constant optimization of energy use with regard to an ultrasonic component is important.
  • an ultrasonic transducer has dual effects, such that the ultrasonic transducer may be considered more of a mixing component for the liquid mass rather than a heater. While heating with an ultrasonic transducer may require more energy than the use of a standard heating unit, the ultrasonic transducer has multiple effects due to the particular effect of ultrasonic radiation on the parts. While regulating the work that the ultrasonic transducer is doing, the device is characterizing. Ultrasonic radiation affects the surface of the part microscopically by causing vibration, thus, the work being done by the ultrasonic generator goes beyond heat alone, and creates a synergistic effect on support removal, causing the removal of support material in less time.
  • Another important feature of the support removal machine of the present disclosure is the inclusion of two linked tanks, an output, or part-containing tank, and an input tank.
  • the liquid mass which may be a detergent, flows from the bottom of the input tank through a manifold into the output tank, generating a pressure and rotational flow within the output tank.
  • the liquid level of the input tank is below that of the output tank, allowing the liquid mass to be discharged from the output tank over barrier between the output tank and the input tank, thereby forming a weir.
  • the weir provides both oxygenation and cooling to the liquid mass; essential functions in maintaining optimal conditions for support removal.
  • the wall separating the two tanks that allow formation of the weir is important because it allows for simultaneous oxygenation and temperature reductions, without the inclusion of additional costly or energy consuming features to regulate these parameters.
  • the liquid mass and the weir cascade rely on the properties of each to maintain a proper balance of oxygenation, pH and evaporation. The machine and liquid mass have been thoroughly tested to optimize the interaction between the weir and the liquid mass.
  • the liquid mass is consumed, and is eventually required to be replaced. Throughout use, however, the level of liquid mass in the output tank is maintained, and kept full. As the liquid mass is consumed, the liquid level of the inflow tank decreases. Once the level decreases to a certain point, a liquid level sensor in the inflow tank is triggered, signaling the operator to replenish the liquid mass.
  • the support removal machine of the present disclosure does not require the user to empty and refill the tank, rather, the conditions of the liquid mass are calibrated such that refilling the inflow tank when the level is decreased to a set point is sufficient to maintain operation of the system virtually indefinitely.
  • FIG. 1 shows a perspective view of the support removal machine in accordance with the present disclosure.
  • FIG. 2 shows a cross-sectional side view of the support removal machine in accordance with the present disclosure.
  • FIGS. 3A-C show a side perspective, magnified and cross sectional view, respectively, of the manifold and nozzle orifice within the support removal machine in accordance with the present disclosure.
  • FIGS. 4A and 4B show side perspective views of the manifold and nozzle orifices in accordance with the present disclosure.
  • FIG. 5 shows a side perspective view of tank drains and cleanout ports in accordance with the present disclosure.
  • FIG. 6 shows a side perspective view the pump and manifold in accordance with the present disclosure.
  • FIG. 7 shows a cross-sectional rear view of the support removal machine in accordance with the present disclosure.
  • FIG. 8 shows a cross-sectional side view of a part at is rotates within a chamber in accordance with the present disclosure.
  • support should be construed in their broadest interpretation to include any material or materials used for provisional support during fabrication of a 3D object and that is not part of the three-dimensional object.
  • the support may include materials that are different than the modeling materials used to fabricate the 3D object or a combination of modeling materials and materials that are different than the modeling materials used to fabricate the 3D object.
  • Support removal machine has a lid 10 , which an operator may open to allow placement of a 3D part 40 (shown in FIG. 8 ) having support material.
  • Control panel 12 allows a user to input initial pre-determined parameters such as temperature and time.
  • Front panel 8 may be opened to allow access to the tanks, pump, and other internal components of support removal machine 100 .
  • FIG. 2 a cross-sectional side view shows various components essential to support removal machine 100 .
  • part 40 When part 40 is placed into support removal machine 100 through lid 10 , it enters output tank 16 , which may be alternatively referred to as a part-containing tank 16 , wherein the part 40 may be contained in parts basket 24 .
  • Output tank 16 is filled with a liquid mass 28 which flows circularly from input tank 18 in response to activation of a pump 30 (shown in FIG. 3A ), which causes the liquid mass 28 to flow under pressure from tank manifold 14 .
  • a pump 30 shown in FIG. 3A
  • PC 13 is shown centrally located in control panel 12 .
  • Ultrasonic generator 70 is shown below output tank 16 .
  • a weir 20 may exist between output tank 16 and input tank 18 .
  • Weir 20 may be comprised of a wall 36 , or attenuating wall for its effect on ultrasound, between output tank 16 and input tank 18 . The flow of liquid mass 28 from output tank 16 to a lower point in input tank 18 over wall 36 creates a passive system for achieving proper temperature and oxygenation states in the liquid mass.
  • a positive pressure in output tank 16 created by flow into output tank 16 from pump 30 generates an overflow across wall 36 without a need for active suction from output tank 16 , thus creating a system that eliminates the potential for damage to part 40 caused by suction from output tank 16 .
  • Liquid level sensor 26 which in some embodiments may be continuous, notifies a user when the liquid mass 28 level needs maintenance.
  • An alternative embodiment may comprise one tank or multiple tanks.
  • a feature of the support removal machine 100 of the present disclosure is the inclusion of two linked tanks, output tank 16 and an input tank 18 , wherein the output tank 16 contains part 40 and the input tank 18 may contain a conditioned liquid mass 28 .
  • liquid mass 28 which may be a detergent, is pumped through a pump 30 from a lower area of input tank 18 through multiple manifolds 14 into output tank 16 , generating a hydraulic pressure and rotational flow within output tank 16 .
  • pump 30 is positioned below input tank 18 . The location of pump 30 may be important because, in one embodiment, pump 30 is not self-priming, and therefore, requires liquid mass 28 to be pumped to feed into pump 30 above the pump inlet.
  • Manifolds 14 are positioned to be capable of directing a flow of liquid mass 28 in order to create a circularized flow, or vortex, in output tank 16 .
  • This flow allows for uniform exposure of all aspects of the part 40 to means of support removal, including, but not limited to, ultrasound, heat, and chemical treatment.
  • no means of suction exists for withdrawal of liquid mass 28 from output tank 16 into input tank 18 during operation.
  • Liquid mass 28 in a preferred embodiment, flows over the weir 20 as liquid mass 28 is pumped from input tank 14 to output tank 16 .
  • pump 30 is a magnetically coupled centrifugal pump. Pump 30 may be placed at a location beneath the level of the input tank 18 or output tank 16 . In one embodiment, pump 30 has a motor that operates at 50/60 Hz and is not adjusted.
  • input tank liquid level 19 is below that of the output tank 16 , allowing the liquid mass 28 to be discharged from the output tank 16 over a wall 36 between the output tank 16 and the input tank 18 , thereby forming a weir 20 .
  • Weir 20 has a wall 36 to separate liquid mass 28 between output tank 16 and input tank 18 .
  • the weir 20 should be located just above upper manifold 14 , allowing the rotational flow to continue within the output tank 16 , while allowing liquid mass 28 to flow over weir 20 in a laminar fashion.
  • the distance between liquid mass 28 level in the output tank 16 and the liquid level in input tank 18 may be between 2 inches and 12 inches.
  • Weir 20 provides both oxygenation and cooling to liquid mass 28 , which are essential functions in maintaining optimal conditions for support removal.
  • the cooling effect of weir 20 allows temperature of liquid mass 28 to be controlled with much tighter tolerances, even at low temperature settings. Weir 20 therefore allows the user to process delicate parts 40 that would normally be in danger of being damaged or altered due to temperature overshoot.
  • Wall 36 which separates output tank 16 and input tank 18 to form weir 20 allows for simultaneous oxygenation, or aeration, and temperature reductions without the inclusion of additional costly or energy consuming features to regulate these parameters.
  • Liquid mass 28 and weir 20 create a cascade to regulate oxygenation, pH and evaporation. Parameters of weir 20 have been optimized for efficiency of support removal.
  • liquid mass 28 As liquid mass 28 is consumed or exhausted through evaporation, mechanical, or chemical or other means, the consumed portion may require replacement.
  • the level of liquid mass 28 in output tank 16 and input tank 18 is therefore monitored and maintained. As the liquid mass 28 is consumed, the liquid level of the input tank 18 decreases. Once the liquid mass 28 level in input tank 18 decreases to a certain point, a liquid level sensor 26 , which may be a continuous liquid level sensor, in input tank 18 is triggered, signaling the operator to replenish or restore liquid mass 28 .
  • the support removal machine 100 of the present disclosure may not require the user to empty and refill the system completely, rather, the conditions of the liquid mass 28 are calibrated such that refilling the system when the level of liquid mass 28 is decreased to a set point may be sufficient to maintain operation of the system indefinitely.
  • Support removal machine 100 may respond automatically to changing conditions within output tank 16 and input tank 18 , and structural changes in the part 40 , while maintaining part 40 in an optimal location within output tank 40 for support removal.
  • the continuous regulation of the position, circulation, and rotation of part 40 occurs in response to output tank 16 parameters, subject to a combination of parameters including liquid mass 28 flow, heat, ultrasound, and measurement capabilities, such that the use of energy in support removal machine 100 is maximized and damage to part 40 is minimized.
  • the flow of liquid mass 28 generated as liquid mass 28 passes through a set of tank manifolds 14 , is generally rotational such that the liquid mass 28 is a vortex and that part 40 does not, due to the rotational flow of liquid mass 28 , generally contact the surface of liquid mass 28 .
  • the position of manifolds 14 and the direction of the flow of liquid mass 28 generated from manifolds 14 creates a vortex that suspends part 40 between a surface of the liquid mass 28 and a bottom and sides of output tank 16 .
  • a single tank having a pump may generate flow to effectively rotate part 40 in a single chamber.
  • FIGS. 3A-C manifolds 14 and nozzle orifices 34 are shown.
  • the position of the manifolds 14 within output tank 16 is important in creating a circular flow of liquid mass 28 .
  • FIG. 3C shows a continuous level sensor 39 , which floats to convey liquid mass level in input tank 18 .
  • Sedimentation plate 37 is shown in FIG. 3C .
  • three manifolds 14 are positioned symmetrically around the output tank, where each manifold 14 is positioned along a different surface of output tank 14 at a junction between two sides of output tank 16 .
  • Two manifolds 14 are positioned on opposite sides, a first and second side, of output tank 14 (as shown in FIG. 4A where nozzle orifices 34 are positioned at 90 degrees on manifolds adjacent opposite sides of output tank 16 ).
  • Adjacent manifolds 14 have a series of in-line nozzle orifices 34 , wherein nozzle orifices 34 are offset 90 degrees on each adjacent manifold 14 , such that the nozzle orifices 34 project liquid mass 28 parallel to adjacent sides, resulting in a rotational flow of liquid mass 28 in three directions at generally 90 degree angles along three sides of output tank 90 .
  • This arrangement of manifolds 14 and orifice nozzles 34 induces a circular, rotational flow of liquid mass 28 and creates a vortex within the output tank 16 .
  • Each manifold 14 may extend the entire width of output tank 16 and may contain a varied number of nozzle orifices 34 along manifold 14 , although embodiments may vary.
  • the number of nozzle orifices 34 , each aligned in-line along manifold 14 is five.
  • the number of manifolds 14 may be important in order to create appropriate pressure on liquid mass 28 in order to produce appropriate rotational flow to maintain part 40 in a central location in output tank 16 .
  • each manifold 14 is fed liquid mass 28 from the pump 30 with equal pressure from pump 30 through manifold inlet 42 , as shown in FIG. 4B .
  • the apparatus and method of the present disclosure may not be limited to a particular number of tanks.
  • Manifolds 14 may extend laterally along the junction between sides of output tank 16 .
  • the manifold 14 has a nozzle orifice 34 .
  • the diameter of nozzle orifice 34 may vary depending on the desired conditions for optimizing liquid mass 28 pressure for support removal.
  • Manifolds 14 and nozzle orifices 34 are positioned generally symmetrically around output tank 16 (as shown in FIG. 2 ) and approximately at an edge along sides or side junctions of output tank 16 in order to propel liquid mass 28 in a plane with sides of output tank 16 such that a vortex is generated to maintain the position of the part 40 centrally within output tank 16 (see FIG. 8 ).
  • Table 1 shows how orifice size effects flow of liquid mass 28 .
  • overflow tank drain 52 is shown. Sediment tank drain 54 is shown. Cleanout ports 56 are shown. The number of outlets for each purpose is not limiting.
  • pump 30 and manifolds 14 are shown.
  • FIG. 7 a cross-sectional rear view shows mechanisms for pumping and filtering the liquid mass 28 .
  • Filter 32 removes particulate matter generated during support removal as pieces of the support break apart.
  • Pump 30 generates the pressure that forces the liquid through tank manifolds 14 .
  • Pump 30 may be a commercially available pump, when used with the support removal machine 100 of the present disclosure, and would not require a custom build. The present disclosure is not limited to commercially available pumps. Pump 30 generates sufficient pressure, without the need for suction within the output tank 16 , to provide rotational flow such that the part is maintained in a centrally located position within output tank 16 .
  • Ultrasonic generator 70 or ultrasonic motor, supplies power for ultrasonic transducers, which may number between 16-24 without limitation.
  • a key functional feature of the present disclosure is the ability to maintain the position of the part 40 in a generally central location in output tank 16 . Maintaining position of part 40 is accomplished through the use of manifolds 14 positioned at locations throughout tank 40 to create a rotational liquid flow, or vortex, that creates liquid current to sinks a part 40 that would otherwise float and to float a part 40 that would otherwise sink. Under the rotational flow conditions generated by the apparatus and method of the present disclosure, a part 40 is centrally located, submerged in a tank and circulated around a central axis of the tank, along with being rotating around an axis of the part 40 .
  • one or more manifolds may be positioned on the walls of the tank at certain locations along output tank 16 including one position immediately adjacent to weir 20 on wall 36 .
  • the location of pump 30 connected to the manifolds 14 , allows for the use of commercially available pumps, rather than custom built pumps, because the manifolds were designed around the performance, or operating abilities, of the pumps.
  • custom built pumps are contemplated within the present disclosure.
  • Rotation of part 40 within the liquid mass 28 creates friction between the materials in the liquid mass 28 and the part 40 , resulting in support removal.
  • support removal is enhanced by ultrasonic transducers 22 placed tangentially in output tank 16 with respect to rotating part 40 .
  • Ultrasonic generator 42 creates heat in liquid mass 28 within output tank 16 , which causes support removal through multiple direct and indirect means, while also causing cavitation through direct interaction with the rotating part 40 .
  • each aspect of part 40 is exposed to ultrasound, thereby creating a synergistic effect in support removal through rotational effects in liquid mass 28 and the ultrasonic enhancement of support removal.
  • FIG. 8 a cross-sectional side view shows the flow of liquid mass 28 during pumping by pump 30 , as indicated by the curved arrows in output tank 16 , along with the concomitant rotation of 3D printed part 40 .
  • 3D printed part 40 rotates in the center of output tank 16
  • different surfaces of 3D part 40 are exposed to tangential radiation from ultrasonic transducer 22 .
  • Ultrasonic transducer 22 interrogates part 40 as part 40 rotates in output tank 16 .
  • Part 40 may be tangential to ultrasonic transducer 22 , and rotation of part 40 allows all aspects of the part 40 to be exposed to ultrasound.
  • Part 40 generally circulates around a central point in output tank 16 , and part 40 rotates.
  • part 40 in output tank 16 creates a controlled agitation.
  • the action of part 40 during this process therefore creates support removal through friction by continuous rotational motion of 3D printed part 40 within the detergent, along with a uniform interrogation from ultrasonic transducer 22 , thereby generating synergy in support removal between the action of the pump, the heater, the chemistry and the ultrasonic transducer.
  • the ultrasonic interrogation of part 40 creates heat and cavitation in a generally uniform manner across the part as it rotates and circulates through output tank 16 , exposing each surface of part 40 to the ultrasound.
  • a heating unit may also be used to generate heat for enhancing support removal.
  • the heating unit and the ultrasonic generator 70 may operate in harmony, such that when the ultrasonic generator 70 needs to be dialed down, the heating unit can compensate by maintaining the heat of the mass at an optimal level.
  • a heating unit may be positioned wherein said heating means comprises a heating element having an internal end positioned internally in the output chamber 16 to engage the liquid mass and an external end communicatively coupled to said microprocessor for controlling heat input to the liquid mass contained within the output chamber 16 .
  • An advantage provided by the use of ultrasound is the creation of cavitation of liquid mass 28 , which a heater and pump 30 may not do. Overuse of the ultrasonic transducer 22 may degrade the liquid mass 28 such that liquid mass 28 becomes exhausted.
  • the part 40 material may be energy sensitive to deforming or delaminating such that constant optimization of energy within the system is important.
  • an ultrasonic transducer 22 has dual effects, such that the ultrasonic transducer 22 may be considered a mixing component for liquid mass 28 rather than an just a heater. While heating with an ultrasonic transducer 22 may require more energy than the use of a standard heating unit, the ultrasonic transducer 22 has multiple effects. Ultrasound affects the surface of part 40 microscopically by causing vibration, thus, the work being done by ultrasonic transducer 22 extends beyond heating alone, thus creating a synergistic effect for support removal, and increasing efficiency of the process.
  • the components comprising the support removal apparatus may be fabricated from a variety of materials, providing such selection or use of materials possess the capacity to withstand premature corrosion given the presence and use of an alkaline aqueous cleaning solution, notably falling within a variety of pH ranges.
  • the tank can be made of 304 and/or 316 SS or any steel alloy with better corrosion resistance than 316 SS. Accordingly, it is most desirable, and therefore preferred, to construct the output tank and input tank work surface, top and nozzle heads from stainless steel; pipe and fittings from a polymeric material such as polyamide (PA) or acrylonitrile-butadiene-styrene (ABS); and cabinet and storage cabinet from a lower grade stainless steel.
  • PA polyamide
  • ABS acrylonitrile-butadiene-styrene
  • the retention tank, nozzle head, work surface, and integral work platform may be alternatively fabricated from materials to lessen the overall weight of the support removal apparatus yet maintaining sufficient resistance to corrosion, such as polypropylene, polyoxymethylene, polyphenylene, ABS, or PA.
  • the pump, thermocouple, heating element 38 , and level indicator, particularly exposed operable components of each are fabricated from a high grade stainless steel or coated with an impervious, corrosive-resistant material such as epoxy.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Physics & Mathematics (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Cleaning By Liquid Or Steam (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
US15/611,435 2016-06-01 2017-06-01 Apparatus and method for support removal Abandoned US20170348910A1 (en)

Priority Applications (11)

Application Number Priority Date Filing Date Title
JP2018562222A JP7000354B2 (ja) 2016-06-01 2017-06-01 支持体を除去するための装置および方法
GB1900079.3A GB2566404B (en) 2016-06-01 2017-06-01 Apparatus and method for support removal
KR1020187034758A KR102398373B1 (ko) 2016-06-01 2017-06-01 서포트 제거를 위한 장치 및 방법
GB2204053.9A GB2601980B (en) 2016-06-01 2017-06-01 Apparatus and method for support removal
GB2115471.1A GB2597397B (en) 2016-06-01 2017-06-01 Apparatus and method for support removal
PCT/US2017/035500 WO2017210460A1 (en) 2016-06-01 2017-06-01 Apparatus and method for support removal
US15/611,435 US20170348910A1 (en) 2016-06-01 2017-06-01 Apparatus and method for support removal
DE112017002807.8T DE112017002807T5 (de) 2016-06-01 2017-06-01 Vorrichtung und Verfahren zur Entfernung von Trägern
ES201890076A ES2711981B2 (es) 2016-06-01 2017-06-01 Aparato y procedimiento para la eliminacion del soporte
US16/519,237 US10737440B2 (en) 2016-06-01 2019-07-23 Apparatus and method for support removal
US16/931,338 US20200391436A1 (en) 2016-06-01 2020-07-16 Apparatus And Method For Support Removal

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US201662344122P 2016-06-01 2016-06-01
US15/611,435 US20170348910A1 (en) 2016-06-01 2017-06-01 Apparatus and method for support removal

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US16/519,237 Continuation US10737440B2 (en) 2016-06-01 2019-07-23 Apparatus and method for support removal

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US20170348910A1 true US20170348910A1 (en) 2017-12-07

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US16/519,237 Active US10737440B2 (en) 2016-06-01 2019-07-23 Apparatus and method for support removal
US16/931,338 Pending US20200391436A1 (en) 2016-06-01 2020-07-16 Apparatus And Method For Support Removal

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US16/931,338 Pending US20200391436A1 (en) 2016-06-01 2020-07-16 Apparatus And Method For Support Removal

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JP (1) JP7000354B2 (es)
KR (1) KR102398373B1 (es)
DE (1) DE112017002807T5 (es)
ES (1) ES2711981B2 (es)
GB (3) GB2601980B (es)
WO (1) WO2017210460A1 (es)

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US11833585B2 (en) 2019-08-12 2023-12-05 Desktop Metal, Inc. Techniques for depowdering additively fabricated parts through vibratory motion and related systems and methods
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KR20190015266A (ko) 2019-02-13
GB2597397B (en) 2022-07-06
GB2597397A (en) 2022-01-26
GB2601980B (en) 2022-08-31
ES2711981B2 (es) 2021-06-08
DE112017002807T5 (de) 2019-03-28
WO2017210460A1 (en) 2017-12-07
GB202204053D0 (en) 2022-05-04
US20200391436A1 (en) 2020-12-17
GB2601980A (en) 2022-06-15
US20190344501A1 (en) 2019-11-14
GB2566404B (en) 2021-12-22
KR102398373B1 (ko) 2022-05-16
GB2566404A (en) 2019-03-13
GB202115471D0 (en) 2021-12-08
JP7000354B2 (ja) 2022-02-04
US10737440B2 (en) 2020-08-11
ES2711981A2 (es) 2019-05-08
JP2019519396A (ja) 2019-07-11
ES2711981R1 (es) 2019-06-07

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