Patent Application
20200061871
The present invention relates generally to additive manufacturing systems and methods and, more particularly, to additive manufacturing systems having automated systems for removing the manufactured parts.
The manufacturing systems widely known as 3D printers operate based on a class of manufacturing techniques known as additive manufacturing. Additive manufacturing differs from subtractive processes (e.g., conventional machining, grinding, lapping) and net-shape processes (e.g., casting, bending, spinning) by incrementally depositing material to achieve desired part geometry. The modern additive manufacturing industry subsumes numerous technologies ranging from selective laser sintering (SLS) to layered object manufacturing (LOM). One of the most widely use forms of additive manufacturing technology is fused filament fabrication (FFF) also known as Fused Deposition Modeling (FDM).
FDM or FFF is just one of many 3D printing or additive manufacturing processes. Other processes include, but are not limited to, SLA, SLS, DMLS, WAAM, nano lithography etc.
3D printing, a form of additive manufacturing, is a laborious manufacturing process in its existing state. First, a user designs a 3-D model using CAD software. The user then manually uploads the .stl (or other equivalent 3D model file format) of the desired 3D part to be made. Next the 3D model is processed by a slicing program to create the machine specific code required by the 3D printer in order to produce the desired 3D printed part. The next step in the process is to upload the machine code to the 3D printer or the 3D printer host program, typically achieved in the form of a program on a computer, the 3D printer, a cloud solution, a thumb drive, or an SD card. From there, the machine code is streamed to a microprocessor on the 3D printer. After the 3D printer is done 3D printing the part, the part is removed manually. In most cases the user is required to use a hand tool, such as but not limited to a paint scraper or knife to remove the 3D part from the print surface.
A fully automated 3-D printer system requires automated part removal so as to eliminate the need for a local human operator to remove a part in order to start a next job. In general the disadvantages of current automated part removal systems are detrimental to the printing process and/or the removal process
Thus, it would be desirable to provide an improved automated removal system for additive manufacturing.
In one embodiment, an additive manufacturing system includes a printing surface for supporting a printed part, and a part removal system, including at least one wire configured to move relative to the printing surface and configured to engage the printed part for removing the printed part from the printing surface. The at least one wire may be configured to be held in constant tension while moving relative to the printing surface. Alternatively, the at least one wire may be configured to be held in variable tension while moving relative to the printing surface. In one embodiment, the at least one wire is configured to be heated while moving relative to the printing surface. In addition or alternatively, the at least one wire may be configured to be electrified while moving relative to the printing surface. In one embodiment, the at least one wire is configured to rotate while moving relative to the printing surface. In addition or alternatively, the at least one wire may be configured to reciprocate while moving relative to the printing surface. The at least one wire may be permitted to vibrate while moving relative to the printing surface. For example, the at least one wire may be controlled to vibrate while moving relative to the printing surface. In one embodiment, the part removal system further includes at least one linear actuator configured to move the at least one wire relative to the printing surface.
In another embodiment, an additive manufacturing system includes a printing surface for supporting a printed part, and a part removal system, including at least one saw configured to move relative to the printing surface and configured to engage the printed part for removing the printed part from the printing surface. The at least one saw may be configured to be held in constant tension while moving relative to the printing surface. Alternatively, the at least one saw may configured to be held in variable tension while moving relative to the printing surface. In one embodiment, the at least one saw is configured to be heated while moving relative to the printing surface. In addition or alternatively, the at least one saw may be configured to be electrified while moving relative to the printing surface. In one embodiment, the at least one saw is configured to rotate while moving relative to the printing surface. In addition or alternatively, the at least one saw may be configured to reciprocate while moving relative to the printing surface. The at least one saw may be permitted to vibrate while moving relative to the printing surface. For example, the at least one saw may be controlled to vibrate while moving relative to the printing surface. In one embodiment, the part removal system further includes at least one linear actuator configured to move the at least one saw relative to the printing surface.
Various additional features and advantages of the invention will become more apparent to those of ordinary skill in the art upon review of the following detailed description of one or more illustrative embodiments taken in conjunction with the accompanying drawings. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the invention and, together with the general description given above and the detailed description given below, serve to explain the one or more embodiments of the invention.
The automated part removal systems described herein apply to any and all types of 3D printing machines or additive manufacturing machines. The rest of this disclosure will be described in the context of the FDM or FFF process workflow and variable. However, it must be noted that to those skilled in the art each different 3D printing or additive manufacturing process can be automated using automated part removal techniques disclosed herein.
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While one or both pulleys 24 (or nonrotatable holders) may travel along the respective rail(s) 30 in a generally linear direction as shown, it will be appreciated that one or both pulleys 24 may travel in any suitable direction and/or be fixed against movement. For example, one pulley 24 (or nonrotatable holder) may be fixed against movement and the other pulley 24 (or nonrotatable holder) may be driven in an arc or semi-circle across the printing surface 12 while maintaining tension in the wire 22.
With reference to
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As described above, the wire or saw 222 is supported for motion across the printing surface 212 to release the part 214 from the printing surface 212. In one embodiment, the wire or saw 222 may be fixed at both ends and held in tension. In one embodiment where the wire or saw 222 is fixed at both ends, the wire or saw 222 may be cantilevered from a support on one side of the printing surface 212 for motion across the printing surface 212. Alternatively, the wire or saw 222 that is fixed at both ends may be supported on both sides of the printing surface 212 for motion across the printing surface 212, as shown. For a cantilevered wire or saw 222 fixed at both ends, the support may form a compliant joint allowing for leveling of the wire or saw 222 fixed at both ends relative to the printing surface 212. In addition or alternatively, the wire or saw 222 may have a hardened steel portion that engages the part 214. In one embodiment, the wire or saw 222 may have a hardened external surface for engaging the 3D printed part 214 on the print surface 212 and the internal core of the wire or saw 222 may be constructed of a softer alloy to allow for compliance, for example.
In any of the aforementioned embodiments, including those having a fixed, rotating, and/or translating wire or saw 22, 122, 222, the wire or saw 22, 122, 222 may be held under constant or variable tension. In one embodiment, the tensioning device may be configured manually. In another embodiment, the tensioning device may be configured automatically or continuously reconfigured so as to maintain a desired or optimal tensioning of the wire or saw 22, 122, 222 for effectively removing the part 14, 114, 214 from the printing surface 12, 112, 212. For example, variable tensioning of the wire 22 or saw 22, 122, 222 may be provided by winding in or out wire or saw lengths from one of the pulleys 24, 124, 224 or via a tensioning screw or other tensioning mechanism, such as in cases where the length of the wire or saw 22, 122, 222 changes during movement of the wire or saw 22, 122, 222 across the printing surface 12, 112, 212.
While the present invention has been illustrated by the description of various embodiments thereof, and while the embodiments have been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Thus, the various features discussed herein may be used alone or in any combination. Additional advantages and modifications will readily appear to those skilled in the art. The present invention in its broader aspects is therefore not limited to the specific details and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope of the general inventive concept.
