Support Removal for 3D Printed Parts

Automated method for removing support structures from 3D printed models without manual intervention. The method involves determining the connection points between the support structure and printed part, generating a cutting path based on those points, and using a tool to separate the printed part from the support structure along the path. This allows automated removal of supports compared to manual methods.

Source

Method to improve the quality of 3D printed objects with support structures by optimizing where the supports are added. The method involves assigning degrees of quality to different surface segments of the 3D model based on factors like surface orientation. Then calculating where supports should be added based on the quality levels. This allows targeted placement of supports that prioritize critical areas over unnecessary ones.

Source

A 3D printing support generation system that allows customization of the support structure around an object being printed. The system generates an initial support structure based on predetermined conditions. The user can then remove portions of the support using an interface. The system regenerates the support data using the modified shape. This allows the user to fine-tune the support locations to avoid unnecessary material and improve print quality.

Source

Method for producing 3D printed objects with automated support structure removal that improves quality and reduces post-processing costs. The method involves selecting a removal strategy based on the object model, modifying the support structure model based on the selected strategy, and using additive manufacturing to form the 3D object with modified supports. After printing, the supports are removed using the selected strategy. This automated support removal is done in-house instead of manual post-processing. The strategy selection is based on estimating process values for each removal method.

Source

A 3D printing support design, method, and removal technique that enables easier and more automated support generation and removal for complex 3D printed parts. The support structure is a series of parallel columnar shapes surrounding the part. This allows for easier separation compared to traditional supports since the columns can be completely removed. It also enables automated support generation and removal using specialized tools since the columns are accessible and uniform. The columns can be printed alongside the part during the 3D printing process. After printing, the columns are detached from the part using the removal technique. This avoids manual support addition and removal and prevents support residue on the printed part surface.

Source

Removing supports from 3D printed metal parts by spraying a water jet onto them immediately after printing. The supports are sequentially stacked around the printed part during printing. After printing is complete, a water jet is sprayed onto the supports to quickly remove them along with any remaining metal powder. This allows easy and quick removal of the supports compared to manual removal or using explosive substances.

Source

A thermally decomposable build plate for additive manufacturing that enables easy release of 3D printed metal parts without damaging the parts or build plate. The build plate is an open frame with a recessed section filled with a lower-temperature melting metal or alloy insert. After printing, the insert can be melted and drained to release the 3D printed part without mechanical cutting. The lower melting insert protects the build plate, allows separation without damage, and reuses the plate.

Source

3D printing method that enables 3D printing complex shaped objects with removable supports. The method involves 3D printing the object using a shaping material like metal or ceramic powder and simultaneously 3D printing supports around the object using a removable resin material. After printing, the supports are removed by heating, vaporizing, or dissolving the resin. This enables the creation of complex 3D shapes with internal voids and overhangs that would otherwise require difficult support removal.

Source

Automatically optimize the support removal process for 3D printed parts by using historical and real-time data from the support removal machine to decide which agitation methods to activate and adjust.

Source

Removing internal support structures from 3D printed objects using flexible hoses that can be inserted into the internal hollows of the printed part. The hose has a channel with an inlet and outlet. When fluid is pumped into the inlet, it exits through the outlet and causes the hose to flail inside the part. This flailing motion fractures the internal support structures. In some cases, a balloon attached to the outlet inflates as fluid exits, further aiding in fracturing the support structures.

Source

A system for precise post-processing of multi-layer 3D printed products like metal parts. The system uses 3D scanning to accurately find the origin of processing for post-machining. It compares 3D scan data of the as-built part with CAD data to determine the relative pose. This pose offset is used to set the machining origin. The system then generates tool paths for support removal and surface finishing starting from the known origin. This allows automated post-processing of complex 3D printed parts with improved accuracy and reduced setup time.

Source

Optimizing the operation of a machine that removes support material from 3D-printed parts to maximize efficiency and avoid damage involves using an operation model that analyzes real-time data from the removal process to identify the best parameters for each consecutive interval of the process.

Source

A method to reduce the number of post-processing steps required after 3D printing is using a multi-layer 3D printing technique. The method involves printing multiple layers simultaneously, rather than one layer at a time, using a 3D printer with multiple print heads. This reduces the need for support structures by allowing overhanging features to be supported by adjacent layers. The simultaneous printing of layers also allows different materials to be printed together. The multi-layer printing technique simplifies post-processing by reducing the need for support removal, sorting, cleaning, and packaging.

Source

Design method for optimizing support structures in additive manufacturing to reduce distortion and deformation of 3D printed parts. The method involves using computer modeling to create a manufacturable support structure that can be 3D printed alongside the part to prevent warping during the additive manufacturing process. The support structure is designed to mitigate temperature gradients and uneven melting that can cause internal stresses and deformations. The support structure is optimized by analyzing factors like thermal conductivity, geometry, and melting rates to create a support that allows the part to cool and solidify uniformly.

Source

Optimizing 3D models for additive manufacturing by reducing support structures. The optimization involves modifying the generated 3D shape during the design process to reduce overhangs and angles that require external support during additive manufacturing. This involves extracting and offsetting 2D profiles of each layer, then modifying the next layer using the offset profiles to produce a larger sized 2D profile. This reduces the amount of geometry violating overhang constraints and encourages shapes with less support.

Source

Post-processing method for removing support structures from 3D printed parts that reduces damage and improves efficiency compared to manual removal. The method involves using the original part design to identify features of the support structures in the actual printed part. Then a plan is generated for removing the supports based on this information. This plan is sent to the robot control system to guide automated removal using tools like mills and chisels.

Source

Automated design generation for additive manufacturing with an accessible support volume. The method involves optimizing the design of 3D printed parts to have removable supports that can be accessed by subtractive manufacturing tools. It uses physics-based analysis to evaluate accessibility and generate plans for removing the supports. The method involves calculating a measure of inaccessibility of the support volume using physics simulations. It then generates designs with accessible supports by filtering and augmenting the decision variables with the inaccessibility measure. This ensures the support volume can be removed using subtractive manufacturing after 3D printing.

Source

Optimized 3D printing to minimize marks from support structures on printed objects. The method involves overcuring regions of the object near the support structures that will remain as marks when supports are removed. By overcuring those regions, the surface is made to project past the marks once the supports are removed, which flattens it to the desired profile. This eliminates the need for post-processing, like sanding, to remove support marks and achieve smooth surfaces.

Source

A method to reduce or eliminate visible support marks on 3D printed objects. The method involves adding overcure regions to the object during printing - regions where extra material is deposited. When the support structures are removed, any remaining support marks are recessed below the overcured regions, leaving a smooth surface.

Source

Removing internal support structures from 3D printed parts to reduce weight and provide flexibility. The method involves inserting demolition objects into the hollow interior of the part, breaking the support structures, changing the demolition objects, then removing them. The demolition objects can be hardened balls that pulverize the supports, melting balls that liquefy and drain out, or shape memory alloys that deform and break. By selecting the right demolition object material and state, it allows efficient removal of broken supports without getting trapped inside.

Source

Optimizing removal of support structures during subtractive manufacturing (SM) after additive manufacturing (AM) to improve efficiency and reduce errors. The process involves capturing data from the AM process like part geometry, support structure contact points, and orientation. This data is then used to generate a tool path for the SM machine to remove the support structures accurately. It allows leveraging the AM data to guide the SM process for better removal of the added support structures.

Source

Optimizing build orientation in hybrid additive-subtractive manufacturing to minimize inaccessible support structures. The method involves determining the support structure needed for additive manufacturing at multiple orientations, selecting an orientation that minimizes the cost of inaccessible support areas using subtractive manufacturing tools, and building the part using the selected orientation for additive manufacturing. This ensures the support can be fully removed using subtractive processes.

Source

A method for efficiently removing unjoined powder and accessing printed objects in 3D printing to simplify post-processing. It involves designing custom support structures for the printed objects that facilitate simultaneous movement and extraction of unjoined powder. The support structures have open configurations with apertures or lattices to allow powder to pass through. This allows automated or manual extraction of unbound powder around multiple objects at once, reducing manual intervention compared to extracting powder around individual objects. The open support structures also enable easier access to the objects for further processing.

Source

Automated generation of 3D modeling and cutting data for additive manufacturing with support structures, without requiring separate support removal steps. The system generates both the 3D modeling data for printing the part and the cutting data for removing the supports using a single program. The supports extend beyond the part and are removed along with the added allowance when cutting. This saves time compared to separately generating and executing support removal steps.

Source

3D printing method with fast and automated support removal to improve print quality and reduce costs. The method involves using a specialized 3D printer with features like a vertical lifting platform, a rotating print head, and a parking mechanism. This allows the printer to automatically raise the platform, rotate the print head, and park the nozzle after each layer to separate the support structures from the printed part. The printer uses a data line to receive the 3D model and execute printing steps. This allows fast and automated support removal without manual intervention or specialized tools.

Source

3D printing method that allows easy removal of support structures from printed objects after sintering without damaging the main object. The method involves modifying the 3D model before printing to add support structures and interfaces with predetermined release forces. This ensures the support structures can be removed with a specific force after sintering. The force is determined based on factors like interface agent strength, support length, applied force direction, and object location. This prevents damage to the object when removing supports. The modified model is then printed using a 3D printer. After sintering, the support structures can be removed using tools with higher resistance than the predetermined force.

Source

Rapidly analyzing the cleanability of 3D printing support structures in any direction to optimize printing orientation. The method involves iteratively traversing the boundary voxels of the 3D model's bounding box to find accessibility gaps for the support structures. If all gaps are found, the supports can be cleaned. If not, some supports are inaccessible. This avoids the need for complex preprocessing and allows quick determination of support cleanability from any angle.

Source

Creating optimized support structures for 3D printed objects that balance providing proper support during fabrication with easy removal after printing. The structure uses tearaway supports that are interconnected but have minor contact points with the object, allowing them to be easily torn off. The supports also have untrussed upper sections and adjustable join geometries to reduce tearing forces.

Source

Optimizing 3D printed designs generated from topology optimization to eliminate unsupported regions that require additional support material during printing. The optimization process involves detecting unsupported elements in the initial topology optimized design using directional kernels that compute material amounts within ranges defined by overhang angles. Local constraints are then imposed on the optimization to remove the detected unsupported elements and generate a final self-supporting CAD model without requiring additional support material during printing.

Source

Calculating the optimal gap distance between support structures and components during powder bed fusion 3D printing to avoid structural connections between the support and the component. The method involves selecting the support surfaces that require support, calculating the gap distance based on component design and process analysis, and using that gap distance to generate optimized support structures. The goal is to prevent the support from fusing to the component during printing.

Source

Method for manufacturing three-dimensional models with simplified support removal. The method involves modeling the structure using a metal or ceramic powder material and forming a support using a resin material. The support is molded and then the structure is modeled while it is being supported by the resin. After modeling is complete, the resin support is degreased by heating, vaporizing, or dissolving to remove it. This allows easier support removal compared to traditional methods where the support is still attached to the model.

Source

A sacrificial support material for 3D printing that can be easily removed from printed objects. It is made from an epoxy resin containing isosorbide diglycidyl ether and a curing agent. The sacrificial support material can be printed alongside the main object and then dissolved away after printing using a solvent that doesn't affect the main object. The isosorbide-based sacrificial support enables complex hollow structures to be 3D printed, that would be difficult or impossible with conventional supports.

Source

A 3D printing method that allows for easy release of support structures without leaving residue or damaging the printed object. It involves applying a low surface energy release material layer onto the object surface before printing. The release layer has a surface energy of 25 mN/m or lower. This prevents adhesion between the printed material and the support material. After printing, the release material can be applied using a separate print head or spraying/coating. The low surface energy release layer allows the supports to be easily detached after printing without residue or damage.

Source

A method for 3D printing hollow objects without defects at internal openings. The method involves analyzing the 3D model data to identify converging internal openings. It then generates a support structure that fills the opening during printing. The support has a thin boundary contour around the internal edge. An interface web spans this contour and defines a weakness that allows easy separation from the printed object. This prevents defects like witness marks at the apex of converging openings.

Source

Optimizing support structures for 3D printing overhangs using a technique called "projection and connection" to reduce material waste and improve print quality. The technique involves projecting support structures from previous layers onto current layers, removing overlaps, and connecting them without crossing the current boundary. This avoids redundant support and ensures a continuous structure. It also adds a height increase to overlapping model paths to prevent bridging issues.

Source

Improved additive manufacturing of 3D objects with features like support structure creation, multi-zone manufacturing, multi-exposure printing, and tool path optimization. The improvements aim to enhance additive manufacturing processes like FDM and SLA by optimizing support structure generation, allowing customized printing parameters for different regions, implementing multi-exposure printing, and optimizing tool paths for temperature and stress. The methods involve analyzing the 3D model to identify regions needing support, selecting the right support type based on stress/warping, dividing the model into zones with customized printing parameters, merging the zones for printing, and optimizing tool paths for temperature and stress.

Source

Using a rotating fluid jet to remove support material from 3D printed objects in a way that is more efficient and less damaging than traditional methods. The method involves inserting the printed objects into a container, then using a rotating fluid jet to vigorously agitate the objects. The jet collisions and turbulence help loosen and remove the support material from the printed objects.

Source

Post-processing technique to remove support material from a 3D printed object without damaging the object. The technique involves heating the printed object to melt the support material, draining off the melted support material, and then immersing the object in a liquid to remove any remaining support material.

Source