Method And Apparatus For Support Removal Using Directed Atomized And Semi-Atomized Fluid

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.

1 . An apparatus for removing support material from and/or smoothing surfaces of an additively manufactured part, comprising:
 a chamber;   a support surface within the chamber, and configured to support an additively manufactured part (the “AM part”); and   one or more nozzles within the chamber, and configured for spraying a fluid at said AM part, wherein said nozzles generate an atomized or semi-atomized spray of said fluid.   
     
     
         2 . The apparatus of  claim 1 , further comprising a tank configured to hold a volume of said fluid, and positioned to capture the fluid after the fluid is sprayed. 
     
     
         3 . The apparatus of  claim 2 , further comprising a heater at least partially within said tank for heating said fluid to a desired temperature. 
     
     
         4 . The apparatus of  claim 1 , wherein said support surface further comprises openings sized and configured to allow said fluid to pass through said one or more openings. 
     
     
         5 . The apparatus of  claim 1 , wherein the nozzles are arranged as two spray-headers of nozzles. 
     
     
         6 . The apparatus of  claim 5 , further comprising:
 a first spray-header of nozzles configured to spray said fluid substantially downward toward the AM part; and   a second spray-header of nozzles configured to spray said fluid substantially upward toward the AM part.   
     
     
         7 . The apparatus of  claim 6 , wherein one or both of said first and second spray-headers of nozzles is connected directly or indirectly to an actuator for translating said spray-header of nozzles back and forth in a planar motion. 
     
     
         8 . The apparatus of  claim 6 , wherein one or both of said first and second spray-headers of nozzles is secured to a mount that is adjustable to move the spray-header nearer to or further away from said support surface. 
     
     
         9 . The apparatus of  claim 8 , wherein one or both of said first and second spray-headers of nozzles is connected directly or indirectly to an actuator for translating said spray-header of nozzles back and forth in a planar motion. 
     
     
         10 . The apparatus of  claim 6 , wherein nozzles of the first spray-header of nozzles are of two or more sizes. 
     
     
         11 . The apparatus of  claim 10 , wherein fluid can flow to spray through first nozzles of one size at the same time that fluid cannot flow to spray through second nozzles of a second size. 
     
     
         12 . The apparatus of  claim 6 , wherein nozzles of the second spray-header of nozzles are of two or more sizes. 
     
     
         13 . The apparatus of  claim 6 , wherein nozzles of the first spray-header of nozzles are of two or more sizes and nozzles of the second spray-header of nozzles are of two or more sizes. 
     
     
         14 . The apparatus of  claim 13 , wherein fluid can flow to spray through first nozzles of one size at the same time that fluid cannot flow to spray through second nozzles of a second size. 
     
     
         15 . The apparatus of  claim 14 , wherein both of the first and second nozzles are associated with the first spray-header of nozzles. 
     
     
         16 . The apparatus of  claim 14 , wherein the first nozzles are associated with the first spray-header of nozzles and the second nozzles are associated with the second spray-header of nozzles. 
     
     
         17 . The apparatus of  claim 1 , further comprising a blower for forcing air into or pulling air out of the chamber. 
     
     
         18 . The apparatus of  claim 1 , further comprising a vent for allowing air to leave the chamber. 
     
     
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         30 . An apparatus for removing support material from or smoothing surfaces of an additively manufactured part, comprising:
 a chamber;   a support surface within the chamber, and configured to support an additively manufactured part;   one or more nozzles within the chamber, and configured for spraying a fluid at said AM part, wherein said nozzles generate an atomized or semi-atomized spray of said fluid; and   an HMI adapted for selection of a desired level of agitation by opening and closing valves to the one or more nozzles.   
     
     
         31 . An apparatus for removing support material from or smoothing surfaces of an additively manufactured part, comprising:
 a chamber;   a support surface within the chamber, and configured to support an additively manufactured part;   one or more nozzles within the chamber, and configured for spraying a fluid at said AM part, wherein said nozzles generate an atomized or semi-atomized spray of said fluid; and   one or more sensors located at or near an inlet to the one or more nozzles for monitoring pressure.