MECHANICALLY BONDING AND THERMALLY RELEASING PRINT SURFACE FOR BIG AREA ADDITIVE MANUFACTURING

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Date

2023

Authors

Weflen, E.D.
Peters, F.E.
Frank, M.C.

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Publisher

University of Texas at Austin

Abstract

Part retention and removal are challenges for Big Area Additive Manufacturing (BAAM) systems, increasing production costs and impacting part quality. A part should remain locked to the print surface during processing and then be released for removal when processing is completed. However, a method for releasing large, multi-meter parts from the print surface on BAAM systems is nonexistent. This work presents a print surface with a mechanically bonding interfacial structure that locks the part to the print surface during processing and then thermally releases the part for removal. Design and process parameters were evaluated, and a model was developed as a design guide for industry implementation. A demonstration casting pattern was produced in a hybrid manufacturing machining center by iterating between polymer pellet-fed material extrusion and surface machining. The viable applications of BAAM can be expanded by improving the process and reducing costs.

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