Approach Analysis And Solution Development For Automated FDM Part Removal Using A Robot Arm

Abstract

Removing completed 3D printed parts from the printer is typically done manually by an operator. This is the case even when dozens or more printers are being used, like in print farms, mainly because there are few affordable and reliable automated solutions commercially available. This thesis discusses why the automated removal of prints is so mechanically challenging and valuable to increasing the efficiency and throughput of Additive Manufacturing Service Providers (AMSPs). In addition, the existing removal solutions for Fused Deposition Modeling (FDM) printers are organized into three categories: build plate relocation, conveyor belt printers, and forced removal. Existing solutions are analyzed, and their advantages and disadvantages are discussed. Using a conveyor belt printer for part removal offers many advantages, though there are issues related to print quality, adhesion, and high rates of failure. Because of these limitations, a prototype for a new approach was designed, fabricated and tested. A custom aluminum build plate with a polyester belt that would remain still during printing on a standard XY gantry FDM printer, but which can be actuated after printing using a robotic arm and custom gripper to remove parts like a conveyor belt printer. Testing showed that the prototype performed similarly to conveyor belt printers without sacrificing print quality