Floating parts with 3D printing

Question

Floating parts with 3D printing

E

E. Begum

21.11.2024 at 10:44

5

Hello ,

I’m using an SLA printer with high-resolution resin (25-micron layer height), for a miniature satellite component prototype, specifically a multi-chamber fluid management system intended for microgravity environments.

The design features intricate internal structures, including floating baffles and valve mechanisms, which are essential for controlling fluid flow. I’m facing challenges with support structures that interfere with these delicate internal components. What strategies do you recommend for optimizing support structures for floating internal components without compromising the part’s functionality or surface finish?
The final product needs to maintain tight tolerances (±0.05 mm) and smooth internal surfaces for optimal fluid dynamics.

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Solved by Damon Ali

The most effective approach is selecting the build orientation to reduce the need for support. While that's pretty obvious advice, if you have much design freedom then you might be able to reorient features to reduce the supports further. Can you break your device into individual chambers that are bonded together after printing? That should give you more freedom with build orientation. Where you can try to minimize undercuts in the areas that do need support. When you say 'floating baffles', can they float on lattice structures you design as supports? Dual-purpose features might reduce the number of supports to remove and clean up.

E

E. Begum

21.11.2024 at 10:44

Hello ,

I’m using an SLA printer with high-resolution resin (25-micron layer height), for a miniature satellite component prototype, specifically a multi-chamber fluid management system intended for microgravity environments.

The design features intricate internal structures, including floating baffles and valve mechanisms, which are essential for controlling fluid flow. I’m facing challenges with support structures that interfere with these delicate internal components. What strategies do you recommend for optimizing support structures for floating internal components without compromising the part’s functionality or surface finish?
The final product needs to maintain tight tolerances (±0.05 mm) and smooth internal surfaces for optimal fluid dynamics.

0

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E

E. Begum

25.11.2024 at 17:19

Damon Ali

Yeah, I’ve done the best I can in these aspects, but I don’t have enough design freedom to lose all the support. I will look at individual chamber builds to reduce the need for support. Sounds structurally and leakage risky, but maybe rewarding.

I like the idea of the baffles being designed to integrate supports, that has real potential.

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C

Chris Jenkins

26.11.2024 at 16:47

E. Begum

Also, thin-walled lattice supports can be left in place with minimized obstruction of fluid flow. Though I would not trust any automated lattice fill tools, model the features fully yourself. Align them with the ideal flow direction you want to impose. Oh, and taper the entry/exit edges to reduce flow influence.

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Damon Ali

29.11.2024 at 16:42

Chris Jenkins

Presumably, you can get access in some areas to break off the supports. Can you increase access by integrating holes and bonded plugs to open up the most difficult areas?

Also, for supports that you are able to break off, you can design them with small, multipoint tapered contact dots or local necking to allow gentle break off and ease cleanup.

Finally, be strategic about placing supports – keep them away from flow-critical zones to reduce any downside flow influence you’re stuck with.

Oh, and I suggest you design all your supports into your model, rather than trusting any automated support structures the printer layout software imposes in the build. No software-built supports can ever have the understanding of the fluid mechanics of the real-use context you’ve got!

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E

E. Begum

03.12.2024 at 08:34

Damon Ali

Thanks, that’s some helpful strategies.

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D

Damon Ali

04.12.2024 at 10:04

E. Begum

It’d be great to see what direction this takes if you could share some details later.

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Hello ,

I’m using an SLA printer with high-resolution resin (25-micron layer height), for a miniature satellite component prototype, specifically a multi-chamber fluid management system intended for microgravity environments.

The design features intricate internal structures, including floating baffles and valve mechanisms, which are essential for controlling fluid flow. I’m facing challenges with support structures that interfere with these delicate internal components. What strategies do you recommend for optimizing support structures for floating internal components without compromising the part’s functionality or surface finish?
The final product needs to maintain tight tolerances (±0.05 mm) and smooth internal surfaces for optimal fluid dynamics.

0
Yeah, I’ve done the best I can in these aspects, but I don’t have enough design freedom to lose all the support. I will look at individual chamber builds to reduce the need for support. Sounds structurally and leakage risky, but maybe rewarding.

I like the idea of the baffles being designed to integrate supports, that has real potential.

0
Also, thin-walled lattice supports can be left in place with minimized obstruction of fluid flow. Though I would not trust any automated lattice fill tools, model the features fully yourself. Align them with the ideal flow direction you want to impose. Oh, and taper the entry/exit edges to reduce flow influence.

0
Presumably, you can get access in some areas to break off the supports. Can you increase access by integrating holes and bonded plugs to open up the most difficult areas?

Also, for supports that you are able to break off, you can design them with small, multipoint tapered contact dots or local necking to allow gentle break off and ease cleanup.

Finally, be strategic about placing supports – keep them away from flow-critical zones to reduce any downside flow influence you’re stuck with.

Oh, and I suggest you design all your supports into your model, rather than trusting any automated support structures the printer layout software imposes in the build. No software-built supports can ever have the understanding of the fluid mechanics of the real-use context you’ve got!

0
It’d be great to see what direction this takes if you could share some details later.

0

Damon Ali · Accepted Answer

The most effective approach is selecting the build orientation to reduce the need for support. While that’s pretty obvious advice, if you have much design freedom then you might be able to reorient features to reduce the supports further. Can you break your device into individual chambers that are bonded together after printing? That should give you more freedom with build orientation.

Where you can try to minimize undercuts in the areas that do need support.

When you say ‘floating baffles’, can they float on lattice structures you design as supports? Dual-purpose features might reduce the number of supports to remove and clean up.

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Vacuum Casting

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Floating parts with 3D printing

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