
Laser powder bed fusion (LPBF) of parts often requires support structures in order to fix overhangs, dissipate heat and reduce deflections due to thermal expansion and resulting residual stresses during laser sintering. The removal of support structures is a manually accomplished tedious work today. Moreover, slender part geometries are prone to be damaged during the support structure removal. In order to overcome these major cost efficiency limitations and achieving reproducible part quality an automated support removal technology has been developed: An oscillating chisel is moved by a robot along those part contours which are equipped with support structures and intermittently separates them. Fundamentals of the impact shear separation are outlined, which allows low impact forces and removal even of slender and intricately accessible supports. The technology is demonstrated on a curved part. Thus, the novel automated support structure removal technology enables a step change in industrial use of laser sintered parts.
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