Influencing factors of removability of support structures using high-frequency vibration

Abstract The removal of support structures in the realm of additive manufacturing poses a significant challenge, particularly in metal 3D printing. Due to the manual removal of support structures, which is predominantly employed in industrial manufacturing companies, the considerable time investment and associated costs for this process step remain significant. Furthermore, handling residual powder or other hazardous materials necessitates high safety standards for employees. Alternative approaches, primarily explored in research settings, exhibit considerable drawbacks due to the use of safety–critical media, excessive impact on the component surface, or the necessity for specialized protective equipment. The vibration-based process outlined in this publication aims to address and mitigate these aforementioned disadvantages, facilitating reliable and customized removal of support structures while simultaneously reducing safety requirements. By introducing vibrations into the component, support structures made of Inconel 718 can be removed using specific frequencies that are aligned with the natural and resonance frequency ranges. This study has demonstrated the potential of this technology through both simulation and practical application, sufficiently highlighting its capabilities, and establishing a foundation for future research.