Material Removal Tool for In-Process Embedding in Additive Manufacturing

This technology provides a novel method for removing unbound material during additive manufacturing to enable in-process embedding of components. By using directed air streams to clear powders, resins, or slurries from targeted regions, the system allows precise cavity preparation without disturbing surrounding structures. This approach expands the design possibilities for 3D-printed parts, supporting advanced manufacturing needs in areas such as electronics, biomedical devices, and multi-material integration. The tool reduces post-processing requirements, improves embedding accuracy, and enhances the adaptability of additive manufacturing platforms.

Description 

Additive manufacturing often involves embedding components, such as sensors or reinforcement structures, within partially completed builds. A persistent challenge is selectively removing loose or unbound material from embedding sites without damaging the surrounding structure. This invention introduces a versatile air-based material removal tool that addresses this problem. 

The tool employs controlled air flow—adaptable for both powder-bed and vat-based systems—to gently or forcefully clear cavities depending on the material environment. For powder-based processes, low-velocity streams minimize disruption to the print bed, while in vat photopolymerization systems, higher flow rates and optional mechanical aids (such as wipers) effectively displace viscous resin.

The system may function as a simple handheld tool for prototyping or as an integrated automated bar assembly for production environments. It is scalable across additive manufacturing platforms and offers flexibility through optional components such as vacuum capture or wiping elements. By providing reliable mid-print cavity clearance, this invention enables accurate and repeatable embedding of diverse objects, paving the way for multifunctional 3D-printed parts.

Benefits

• Precise clearing of cavities for in-process embedding
• Adaptable across powder and resin-based additive systems
• Reduces post-processing requirements
• Scalable for manual or automated use

Applications and Industries

• Biomedical devices and implants
• Embedded electronics and sensors
• Aerospace and defense components
• Advanced materials and hybrid part fabrication

Contact

To learn more about this technology, email partnerships@ornl.gov or call 865-574-1051.