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

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.