Methods for Support Removal in Stereolithographic Additive Manufacturing
The technology presented improves additive manufacturing processes by introducing optimized techniques for removing support structures during the fabrication of 3D objects. Additive manufacturing finds applications in various industries, including medicine, product design, aerospace, and cinematography.
Researchers
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systems and methods for support removal in stereolithographic additive manufacturing
United States of America | Granted | 11,884,004
Figures
Schematic views of embodiments that utilize light sources to modulate mechanical properties at the interfaces between support structures and 3D objects.
Flowchart demonstrating a selective swelling method of separation that uses a dual wavelength cure approach to vary resistance to solvent.
Technology
Each of the removal methods proposed in this technology includes modulating the properties at the interfaces between the support structures and 3D objects. In one embodiment of the technology, the intensity of light can be varied between the two, causing strength discrepancies and allowing for separation. Another approach involves creating a notch—a geometric shape in material—that concentrates the separation to a specific location. Using two different materials for the support structures and 3D objects is another effective method for altering mechanical properties at the interface. For example, one material might partially cure, hardening at a different light wavelength than the other. Alternatively, one material may be more resistant to swelling, so that upon immersion into solvent, the differences in swelling initiates separation. In essence, these methods focus on altering mechanical properties at the interface to allow for optimized separation of support structures and 3D objects. Thus, this technology guarantees the manufacture of 3D objects with desired functionality while upholding high surface quality.
Problem Addressed
Stereolithographic additive manufacturing involves the fabrication of 3D structures, which often require support during the building process. Current methods of removing support structures from 3D objects after completion of printing are suboptimal, requiring labor- and time-intensive manual removal. The manual removal can leave residual stubs that must be polished or sanded down. Moreover, since both support and 3D structures are often made of the same material, automated removal methods like dissolution are prevented. This new technology addresses these limitations by providing efficient methods for the removal of support structures.
Advantages
- Efficient removal of support structures significantly reduces if not eliminates manual labor.
- Part functionality and high surface quality of parts is preserved.
- Removed need for polishing and sanding.
- The manufacturing of 3D objects is more time efficient.
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