Methods for removing and reclaiming unconsolidated material from substrates following fabrication of objects thereon by programmed material consolidation techniques

Abstract

Methods for cleaning consolidatable material from substrates or from features that have been fabricated with the material include application of pressure, force, or a cleaning agent to the substrate or feature. The pressure, force, or cleaning agent may be applied in a variety of ways. The unconsolidated material that has been removed from the substrate or feature may also be collected, optionally filtered, and reused in a subsequent programmed material consolidation process.

1 . A method for removing material in an unconsolidated state from a substrate having at least one feature thereon, comprising: 
 applying force to a material in an unconsolidated state on at least one of a substrate or at least one feature comprising the material in an at least partially consolidated state.    
   
   
       2 . The method of  claim 1 , wherein applying force comprises applying a centrifugal force to the material in the unconsolidated state.  
   
   
       3 . The method of  claim 2 , wherein applying centrifugal force comprises spinning the substrate.  
   
   
       4 . The method of  claim 1 , wherein applying force comprises applying force sufficient to reduce adhesion of the material in the unconsolidated state to at least one of the substrate and the at least one feature.  
   
   
       5 . The method of  claim 1 , wherein applying force comprises applying force sufficient to substantially remove the material in the unconsolidated state from at least one of the substrate and the at least one feature.  
   
   
       6 . The method of  claim 1 , further comprising: 
 collecting the material in the unconsolidated state removed from at least one of the substrate and the at least one feature.    
   
   
       7 . The method of  claim 6 , further comprising: 
 returning the material in the unconsolidated state to a quantity of unconsolidated, consolidatable material to be used for subsequent programmable material consolidation fabrication.    
   
   
       8 . The method of  claim 7 , further comprising: 
 filtering the material in the unconsolidated state following collecting and before or during returning.    
   
   
       9 . The method of  claim 1 , further comprising: 
 cleaning residual material in the unconsolidated state from at least one of the substrate and the at least one feature.    
   
   
       10 . The method of  claim 9 , wherein cleaning comprises applying at least one cleaning agent onto at least one of the substrate and the at least one feature.  
   
   
       11 . The method of  claim 10 , wherein applying comprises directing the at least one cleaning agent onto at least one of the substrate and the at least one feature.  
   
   
       12 . The method of  claim 11 , wherein directing comprises spraying the at least one cleaning agent onto at least one of the substrate and the at least one feature.  
   
   
       13 . The method of  claim 10 , wherein applying comprises at least partially immersing the substrate in a quantity of the at least one cleaning agent.  
   
   
       14 . The method of  claim 13 , wherein cleaning further comprises agitating at least one of the substrate and the at least one cleaning agent.  
   
   
       15 . The method of  claim 10 , further comprising: 
 removing the at least one cleaning agent from at least one of the substrate and the at least one feature.    
   
   
       16 . The method of  claim 15 , wherein removing comprises applying pressure to the at least one cleaning agent.  
   
   
       17 . The method of  claim 16 , wherein applying pressure comprises applying positive air pressure.  
   
   
       18 . The method of  claim 16 , wherein applying pressure comprises applying negative air pressure.  
   
   
       19 . The method of  claim 15 , wherein removing comprises applying force to the at least one cleaning agent.  
   
   
       20 . The method of  claim 19 , wherein applying force comprises applying a centrifugal force.  
   
   
       21 . The method of  claim 20 , wherein applying centrifugal force to the at least one cleaning agent is effected at a first elevation over the fabrication site.  
   
   
       22 . The method of  claim 21 , wherein applying centrifugal force is effected at a second elevation over the fabrication site, the second elevation differing from the first elevation.  
   
   
       23 . The method of  claim 22 , further comprising: 
 preventing introduction of the at least one cleaning agent into the fabrication site.    
   
   
       24 . A method for cleaning material in an unconsolidated state from a substrate having at least one feature comprising the material in an at least partially consolidated state thereon, comprising: 
 applying at least one cleaning agent to at least one of a substrate and at least one feature comprising the material in an at least partially consolidated state.    
   
   
       25 . The method of  claim 24 , wherein applying comprises directing the at least one cleaning agent onto at least one of the substrate and the at least one feature.  
   
   
       26 . The method of  claim 25 , wherein directing comprises spraying the at least one cleaning agent onto at least one of the substrate and the at least one feature.  
   
   
       27 . The method of  claim 24 , wherein applying comprises at least partially immersing at least one of the substrate and the at least one feature in a quantity of the at least one cleaning agent.  
   
   
       28 . The method of  claim 27 , further comprising: 
 agitating at least one of the substrate, the at least one feature, and the at least one cleaning agent.    
   
   
       29 . The method of  claim 24 , further comprising: 
 removing the at least one cleaning agent from at least one of the substrate and the at least one feature.    
   
   
       30 . The method of  claim 29 , wherein removing comprises applying pressure to the material in the unconsolidated state.  
   
   
       31 . The method of  claim 30 , wherein applying pressure comprises applying positive air pressure.  
   
   
       32 . The method of  claim 30 , wherein applying pressure comprises applying negative air pressure.  
   
   
       33 . The method of  claim 29 , wherein removing comprises applying force to the at least one cleaning agent.  
   
   
       34 . The method of  claim 33 , wherein applying force comprises applying a centrifugal force.  
   
   
       35 . A method for recovering material in an unconsolidated state from a substrate upon which at least one feature comprising the material in an at least partially consolidated state has been fabricated, comprising: 
 collecting material in an unconsolidated state from the substrate; and    returning the material in the unconsolidated state to at least one of a fabrication site and a reservoir in communication with the fabrication site.    
   
   
       36 . The method of  claim 35 , wherein collecting includes applying a negative pressure to the substrate to remove the material in the unconsolidated state therefrom.  
   
   
       37 . The method of  claim 35 , wherein collecting includes introducing the material in the unconsolidated state into a conduit.  
   
   
       38 . The method of  claim 37 , wherein returning comprises transporting the material in the unconsolidated state along the conduit.  
   
   
       39 . The method of  claim 38 , wherein transporting is effected with at least one pump.  
   
   
       40 . The method of  claim 38 , further comprising: 
 filtering the material in the unconsolidated state before or during the returning.    
   
   
       41 . The method of  claim 35 , wherein returning comprises applying pressure to the material in the unconsolidated state.  
   
   
       42 . The method of  claim 21 , wherein applying pressure comprises pumping the material in the unconsolidated state.  
   
   
       43 . The method of  claim 35 , further comprising: 
 filtering the material in the unconsolidated state before or during the returning.