Abstract: A process for removing support material from a part made by an additive manufacturing process is disclosed. The part may be arranged in a media filled tank. Ultrasonic waves are directed for the part and/or support material. Ultrasonic waves from an ultrasonic transducer are applied to a part or support material and cause the part to vibrate. The frequency of the ultrasonic energy may be tuned to cause the part and/or the support material to vibrate at its resonant frequency. The support material may have different properties, such as density, geometry, material, or porosity. Such differences may allow the support material to resonate in response to the applied ultrasonic energy waves at a different ultrasonic frequency than, the part itself.

Abstract: Methods and systems according to the invention may be used to modify a manufacturing plan for an object manufactured by an additive manufacturing process. A digital representation of a desired object and a manufacturing plan may be compared to manufacturing information generated via an evaluation of such an object. Based on that comparison, the manufacturing plan may be modified so that that object or a subsequent object is highly similar to the desired object.

Abstract: A process for support material removal for 3D printed parts wherein the part is placed in a media filled tank and support removal is optimized in a multi-parameter system through an artificial intelligence process which may include, but is not limited to, the use of historical data, parametric testing data, normal support removal data, and outputs from other support removal AI models to generate optimally efficient use of each parameter in terms of pulse repetition interval (PRI) and cycle time as defined by pulse width (PW). The input parameters may include heat, circulation, ultrasound and chemical reaction, which are used in sequence and/or in parallel, to optimize efficiency of support removal. Sequentially and/or in parallel, heat, pump circulation and ultrasound may vary in application or intensity. Selection of means of agitation depends on monitored feedback from the support removal tank and application of a statistically dynamic rule based system (SDRBS).

Abstract: An apparatus and method for removing support material from and/or smoothing surfaces of an additively manufactured part (the “AM part”) is disclosed. The apparatus may include a chamber, a support surface within the chamber, and one or more nozzles within the chamber. The nozzles may be the same size or different sizes. The support surface may be configured to support the AM part. The support surface may have one or more openings sized and configured to allow the fluid to pass through the opening(s). The nozzles may be configured to spray a fluid at the AM part, and the spray may be an atomized or semi-atomized spray of the fluid.

Abstract: A method and an apparatus for detecting whether a liquid comprising one or more improper substances or an improper amount of one or more substances has been added to a system for removing support material from and/or smoothing a surface of a part made by additive manufacturing. The apparatus may have a sample material that is altered if the improper fluid contacts the sample material. The alteration may be due to characteristics of the improper fluid at the time the improper fluid is added to the system. In some embodiments of the invention, the sample material is capable of chemically reacting with the improper fluid. The apparatus also includes a sensor capable of detecting whether the sample material has been altered.

Abstract: Apparatuses and methods for removing support material from and/or smoothing surfaces of an additive-manufactured part are disclosed. Apparatuses may include a spraying chamber, a support surface within the spraying chamber, and one or more nozzles having the ability to spray a fluid at the additive-manufactured parts. The fluid may include a liquid and solid particles carried by the liquid. The support surface may have the ability to support the additive manufactured part. The apparatus may include a tank having the ability to hold at least some of the fluid. A heater may be included for heating the fluid to a desired temperature.