Apparatus and method for support removal

Abstract

An apparatus and method for removing support material from a part formed by three-dimensional (3D) printing. The support removal machine contains a tank for submersion of a 3D printed part into a liquid mass. The liquid mass circulates in the tank in a controlled manner such that submerged parts remain centrally suspended in the tank, regardless of the material, density and geometry comprising the part. The part circulates and rotates in conjunction with the rotational flow of the liquid mass for uniform exposure to means of support removal. During rotation, the part may be subjected to multiple means of agitation that include heat, chemical and ultrasonic, in order to optimize energy use and maximize efficiency of the removal of support material.

I claim: 
     
         1 . A method of removing support structure material, comprising:
 providing a part-containing tank;   filling the part-containing tank with a liquid mass;   generating a vortex in the liquid mass contained in the part-containing tank;   placing a part in the part-containing tank;   suspending the part in the liquid mass within the vortex; and   removing support material from the part.   
     
     
         2 . The method of  claim 1 , wherein the part-containing tank has a first side, a second side and a bottom surface; wherein the first side is opposite the second side; wherein a first manifold is positioned at a top portion of the first side and is configured to direct a downward flow of liquid mass along the first side; wherein a second manifold is proximal to a junction between the first side and the bottom surface and is configured to direct a lateral flow of liquid mass along the bottom surface toward the second side. 
     
     
         3 . The method of  claim 2 , wherein the part-containing tank has a third manifold proximal to a junction between the second side and the bottom surface and is configured to direct an upward flow of liquid mass along the second side. 
     
     
         4 . The method of  claim 3 , wherein each manifold directs a flow of liquid mass under equal pressure. 
     
     
         5 . The method of  claim 3 , wherein each manifold has an orifice; wherein each orifice has an orifice diameter; wherein each orifice diameter is capable of being changed to produce an optimal flow of liquid mass for maintaining a part in proper position within the part-containing tank. 
     
     
         6 . The method of  claim 1 , further comprising providing a part-containing tank in fluid communication with an input tank while leaving a build material undisturbed. 
     
     
         7 . The method of  claim 6 , further comprising filling the input tank and part-containing tank with a liquid mass, wherein the level of liquid mass in the input tank is lower than the level of liquid mass in the part-containing tank. 
     
     
         8 . The method of  claim 7 , further comprising pumping the liquid mass from the input tank into the part-containing tank through a plurality of manifolds. 
     
     
         9 . The method of  claim 8 , further comprising discharging the liquid mass from the part-containing tank to the input tank at an upper portion of the output tank; 
     
     
         10 . The method of  claim 1 , further comprising dropping the liquid mass from the part-containing tank into the input tank. 
     
     
         11 . The method of  claim 1 , further comprising pumping the liquid mass into the part-containing tank through a plurality of manifolds positioned symmetrically in order to generate a vortex within the liquid mass. 
     
     
         12 . The method of  claim 1 , wherein each nozzle in the tank directs flow generally within a same plane. 
     
     
         13 . A method of removing support structure material, comprising:
 providing an output tank in fluid communication with an input tank;   filling the input tank and output tank with a liquid mass, wherein the level of liquid mass in the input tank is lower than the level of liquid mass in the output tank;   pumping the liquid mass from the input tank into the output tank through at least one manifold;   forming a vortex in the liquid mass contained in the output tank;   discharging the liquid mass from the outlet tank to the input tank at an upper portion of the output tank;   dropping the liquid mass from the output tank into the input tank;   placing a part in the output tank;   suspending the part in the output tank below the surface of the liquid mass within the vortex;   rotating the part in the output tank with hydraulic pressure;   and removing support material from the part.   
     
     
         14 . The method of  claim 13 , further comprising interrogating the part with ultrasound. 
     
     
         15 . The method of  claim 13 , further comprising oxygenating the liquid mass during transfer from the output tank to the input tank. 
     
     
         16 . The method of  claim 13 , further comprising cooling the liquid mass during transfer from the output tank to the input tank. 
     
     
         17 . A support structure removal apparatus, comprising:
 an output tank having walls and a base collectively forming an output tank chamber for containing a liquid mass and a part;   an input tank having walls and a base collectively forming an input tank chamber; wherein the output tank chamber and the input tank chamber are in liquid communication;   a pump for causing liquid to flow from the input tank to the output tank;   manifolds for producing rotational flow in the output tank;   a weir between the output tank and the input tank, wherein the level of liquid mass is in the input tank is higher than the level of the liquid mass in the input tank;   an ultrasonic motor in the output tank to provide tangential ultrasonic radiation to the part.   
     
     
         18 . The support structure removal apparatus of  claim 18 , further comprising a level indicator positioned internally in said input chamber at a predetermined distance above said agitating means for transmitting level measurements of the aqueous cleaning solution present in said interior chamber to said microprocessor. 
     
     
         19 . The support structure removal apparatus of  claim 18 , wherein the pump is attached to intake and outlet piping passing through intake and outlet apertures wherein the intake aperture is in a wall of the input tank, and the outlet aperture is in a wall of the output tank, wherein the outlet piping has one end attached to outlet side of a pump and a manifold. 
     
     
         20 . The support structure removal apparatus of  claim 18 , further comprising a basket positioned within the output chamber, having perforated walls to permit passage of the liquid mass and inhibiting the passage of parts, and a parts opening extending through one of its perforated walls to permit access to an interior portion thereof, said basket further comprising an overall geometric configuration substantially capable of fitting through the confines of an opening for positioning within the output chamber.