Fluid-based removal of inner support structures manufactured by fused deposition modeling: an investigation on factors of influence

Additive manufacturing is growing in importance in industrial environments. In this context, a holistic process control is required. The process steps in additive manufacturing are generally data preparation, production, and post-production. If there are overhanging geometric elements in the components to be manufactured, they must be supported. The type of support is technology-specific. In fused deposition modeling, a support structure is simultaneously built to accommodate such geometric elements. The support structure may be mechanically removed in post-processing or in a bath of alkaline solution. For inner support cores with complex geometries, a removal in a liquid bath is preferred for reasons of accessibility. However, sufficient contact with the liquid solution is not always given. Consequently, the removal in these cases is not guaranteed. Information about the duration and quality of removal is currently not precisely quantified. An approach to systemize this process is presented in this paper. Therefore potential factors of influence are listed. Selected parameters and their effects were analyzed in experimental trials. The experiments were designed around removing the support material using injection nozzles. The experimental results show the significant impact of pressure, flow rate, and size of contact area on duration and quality of removal. (C) 2015 The Authors. Published by Elsevier B.V.