Patent Description:
The present disclosure pertains generally to an apparatus and method for removing support material from a part formed by three-dimensional printing.

Various systems exist for removing support material from a 3D printed part. These systems often relate to methods for agitating a 3D printed part in a liquid media designed to erode support material surrounding the part. Additional known methods of support removal for three dimensional objects include raising and lowering temperature in a support removal tank to melt the support material, where the support material has a lower melting point than the part. Known systems may utilize a single tank into which the raw part is submerged, or they may include multiple tanks having different properties, including differing temperature or liquids.

<CIT>discloses a method for removing the support structures from 3D objects using a liquid jet. The '<NUM> process generally involves inserting two or more objects made by solid freeform fabrication into a cell having an inlet to receive a high-pressure liquid jet located at a top side of the cell and a plurality of draining perforations at the circumferential wall of the cell.

<CIT>discloses a support structure removal system comprising a reservoir tank and base unit. The vessel comprises a vessel body, a porous floor configured to retain a 3D part, and an impeller rotatably mounted below the porous floor. The impeller is rotated under magnetic force to agitate the solution around the part. Further, the tank may have a means for adjusting pH and temperature to promote support removal.

<CIT>discloses a device for support removal using liquid agitation and heat in a tank. Communication between a thermocouple in the tank and a microprocessor monitors the temperature in the tank and adjusts conditions accordingly.

The above systems often require manual adjustment throughout the process to adjust for various parts. The above systems may be optimally designed for certain types of parts, and may work well for parts of known and tested sizes, shapes and materials. However, when new types of parts are introduced to the system, much adjustment in setting parameters such as heat, pH, and time is required on the part of the operator to optimize efficient use of energy and time.

Therefore, the drawbacks of the current support removal systems include a lack of efficiency when used for a wide variety of parts. Further, movement of the center of mass of the part throughout the tank increases inefficiency and provides an opportunity for delicate parts to collide with the walls of the tank or components of the machine. Such collisions may cause the part to fracture, and also increase inefficiency through uncontrolled movement within the tank.

Efficient support removal for a wide variety of materials and part shapes and sizes requires a system that is responsive to changes in the part and the working environment surrounding the part. Further, a system is desired that can measure the parameters of the part, either directly or indirectly, and adjust automatically to unique properties of each part. Therefore, a need exists for a support removal machine that can efficiently handle the wide and expanding variety of part types encountered in the fast-growing field of three dimensional printing. <CIT> discloses a method in accordance with the preamble of claim <NUM>.

The invention is a method according to claim <NUM>. Further embodiments are disclosed by the dependent claims.

In the present disclosure, a solution to the problems of existing support removal devices is provided through a machine design that maximizes energy efficiency. The present disclosure describes a support removal machine that responds automatically to changing conditions within a tank and structural changes in the part while maintaining the part in optimal location within the tank for support removal. The continuous regulation of part motion and tank parameters, through a novel combination of liquid flow, heat, ultrasonic radiation, and measurement capabilities, maximizes the use of energy and minimizes damage to the part.

Hydraulic pressure oscillates and suspends a 3D printed part while interrogating with ultrasonic frequencies. A key functional feature of the present disclosure is the ability to maintain the position of the part in a generally central location in the tank. This is accomplished through the use of manifolds positioned at specific locations throughout the tank to create a rotational liquid flow that creates liquid current that sinks parts that would otherwise float and floats parts that would otherwise sink. Under these rotational flow conditions, parts are centrally located submerged in the tank and rotate along with the flow of the liquid. In one embodiment, one or more manifolds may be located at the bottom of the tank along with one on the weir wall. The locations of the pump connected to the manifolds allows for the use of commercially available pumps, rather than custom built pumps, because the manifolds were designed around the pumps.

Rotation of the part within the liquid mass creates friction between the materials in the liquid mass and the part, thereby causing support removal. Support removal is enhanced by ultrasonic transducers placed tangentially in the tank to the rotating object. The ultrasonic generators create heat within the designated liquid mass within the tank, which enhances support removal, while also causing cavitation through direct interaction with the rotating part. The part generally circulates around a central point in a tank, and the part itself rotates. The motion of the part in the tank creates a controlled agitation. As the part spins and circulates within the mass, each aspect of the part is exposed to the ultrasonic waves, thereby creating a synergistic effect in support removal through the circulatory and rotational effects of part motion and the ultrasonic enhancement of support destruction.

The ultrasonic interrogation of the part creates heat and cavitation in a generally uniform manner across the part. However, a heating unit in the tank is also used to generate heat for support removal. The heating unit and the ultrasonic generator operate in harmony, such that when the ultrasonic generator needs to be dialed down, the heater can compensate by maintaining the heat of the mass at an optimal level. An advantage of using ultrasonic radiation resulting cavitation of the liquid mass, which a heater and pump will not create. Overuse of an ultrasonic device can degrade the liquid mass such that the fluid becomes exhausted. The part material is energy sensitive to deformation or delaminating so the constant optimization of energy use with regard to an ultrasonic component is important.

The use of an ultrasonic transducer has dual effects, such that the ultrasonic trasducer may be considered more of a mixing component for the liquid mass rather than a heater. While heating with an ultrasonic transducer may require more energy than the use of a standard heating unit, the ultrasonic transducer has multiple effects due to the particular effect of ultrasonic radiation on the parts. While regulating the work that the ultrasonic transducer is doing, the device is characterizing. Ultrasonic radiation affects the surface of the part microscopically by causing vibration, thus, the work being done by the ultrasonic generator goes beyond heat alone, and creates a synergistic effect on support removal, causing the removal of support material in less time.

Another important feature of the support removal machine of the present disclosure is the inclusion of two linked tanks, an output, or part-containing tank, and an input tank. The liquid mass, which may be a detergent, flows from the bottom of the input tank through a manifold into the output tank, generating a pressure and rotational flow within the output tank. Importantly, there is no suction means to withdraw fluid from the output tank during operation. Fluid from the output tank continually flows from the output tank back into the input tank over a weir at the top of the outflow tank.

Therefore, the liquid level of the input tank is below that of the output tank, allowing the liquid mass to be discharged from the output tank over barrier between the output tank and the input tank, thereby forming a weir. The weir provides both oxygenation and cooling to the liquid mass; essential functions in maintaining optimal conditions for support removal. The wall separating the two tanks that allow formation of the weir is important because it allows for simultaneous oxygenation and temperature reductions, without the inclusion of additional costly or energy consuming features to regulate these parameters. The liquid mass and the weir cascade rely on the properties of each to maintain a proper balance of oxygenation, pH and evaporation. The machine and liquid mass have been thoroughly tested to optimize the interaction between the weir and the liquid mass.

Through use of the machine, the liquid mass is consumed, and is eventually required to be replaced. Throughout use, however, the level of liquid mass in the output tank is maintained, and kept full. As the liquid mass is consumed, the liquid level of the inflow tank decreases. Once the level decreases to a certain point, a liquid level sensor in the inflow tank is triggered, signaling the operator to replenish the liquid mass. Unlike other support removal machines and systems, the support removal machine of the present disclosure does not require the user to empty and refill the tank, rather, the conditions of the liquid mass are calibrated such that refilling the inflow tank when the level is decreased to a set point is sufficient to maintain operation of the system virtually indefinitely.

Preferred embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:.

In the following description, the various embodiments of the present invention will be described in detail. However, such details are included to facilitate understanding of the invention and to describe exemplary embodiments for implementing the invention. Such details should not be used to limit the invention to the particular embodiments described because other variations and embodiments are possible while staying within the scope of the invention.

Furthermore, although numerous details are set forth in order to provide a thorough understanding of the present invention, it will be apparent to one skilled in the art that these specific details are not required in order to practice the present invention. In other instances details such as, well-known methods, types of data, protocols, procedures, components, networking equipment, processes, interfaces, electrical structures, circuits, etc. are not described in detail, or are shown in block diagram form, in order not to obscure the present invention.

The terms "support", "support material" and "support structure" as used throughout the specification and claims should be construed in their broadest interpretation to include any material or materials used for provisional support during fabrication of a 3D object and that is not part of the three-dimensional object. The support may include materials that are different than the modeling materials used to fabricate the 3D object or a combination of modeling materials and materials that are different than the modeling materials used to fabricate the 3D object.

Referring now to <FIG>, one embodiment of a support removal machine in accordance with the present invention is shown. Support removal machine has a lid <NUM>, which an operator may open to allow placement of a 3D part <NUM> (shown in <FIG>) having support material. Control panel <NUM> allows a user to input initial pre-determined parameters such as temperature and time. Front panel <NUM> may be opened to allow access to the tanks, pump, and other internal components of support removal machine <NUM>.

Referring now to <FIG>, a cross-sectional side view shows various components essential to support removal machine <NUM>. When part <NUM> is placed into support removal machine <NUM> through lid <NUM>, it enters output tank <NUM>, which may be alternatively referred to as a part-containing tank <NUM>, wherein the part <NUM> may be contained in parts basket <NUM>. Output tank <NUM> is filled with a liquid mass <NUM> which flows circularly from input tank <NUM> in response to activation of a pump <NUM> (shown in <FIG>), which causes the liquid mass <NUM> to flow under pressure from tank manifold <NUM>. In some embodiments, there may only be a single tank, which may be referred to as a part-containing tank <NUM>. PC <NUM> is shown centrally located in control panel <NUM>. Ultrasonic generator <NUM> is shown below output tank <NUM>.

During operation of support removal machine <NUM>, energy of liquid mass <NUM> may be regulated, and oxygenation, or aeration, of liquid mass <NUM> may maintain proper chemistry. To avoid introducing additional components to oxygenate (aerate) and decrease temperature when necessary, a weir <NUM> may exist between output tank <NUM> and input tank <NUM>. Weir <NUM> may be comprised of a wall <NUM>, or attenuating wall for its effect on ultrasound, between output tank <NUM> and input tank <NUM>. The flow of liquid mass <NUM> from output tank <NUM> to a lower point in input tank <NUM> over wall <NUM> creates a passive system for achieving proper temperature and oxygenation states in the liquid mass. A positive pressure in output tank <NUM> created by flow into output tank <NUM> from pump <NUM> generates an overflow across wall <NUM> without a need for active suction from output tank <NUM>, thus creating a system that eliminates the potential for damage to part <NUM> caused by suction from output tank <NUM>. There is a negative pressure in input tank <NUM> that corresponds to the positive pressure in output tank <NUM>. During operation of support removal machine <NUM> the liquid mass will naturally evaporate. Liquid level sensor <NUM> which in some embodiments may be continuous, notifies a user when the liquid mass <NUM> level needs maintenance. An alternative embodiment may comprise one tank or multiple tanks.

In a preferred embodiment, a feature of the support removal machine <NUM> of the present disclosure is the inclusion of two linked tanks, output tank <NUM> and an input tank <NUM>, wherein the output tank <NUM> contains part <NUM> and the input tank <NUM> may contain a conditioned liquid mass <NUM>. In the preferred embodiment, liquid mass <NUM>, which may be a detergent, is pumped through a pump <NUM> from a lower area of input tank <NUM> through multiple manifolds <NUM> into output tank <NUM>, generating a hydraulic pressure and rotational flow within output tank <NUM>. In a preferred embodiment, pump <NUM> is positioned below input tank <NUM>. The location of pump <NUM> may be important because, in one embodiment, pump <NUM> is not self-priming, and therefore, requires liquid mass <NUM> to be pumped to feed into pump <NUM> above the pump inlet. Manifolds <NUM> are positioned to be capable of directing a flow of liquid mass <NUM> in order to create a circularized flow, or vortex, in output tank <NUM>. This flow allows for uniform exposure of all aspects of the part <NUM> to means of support removal, including, but not limited to, ultrasound, heat, and chemical treatment. In a preferred embodiment, no means of suction exists for withdrawal of liquid mass <NUM> from output tank <NUM> into input tank <NUM> during operation. Liquid mass <NUM>, in a preferred embodiment, flows over the weir <NUM> as liquid mass <NUM> is pumped from input tank <NUM> to output tank <NUM>. In a preferred embodiment, pump <NUM> is a magnetically coupled centrifugal pump. Pump <NUM> may be placed at a location beneath the level of the input tank <NUM> or output tank <NUM>. In one embodiment, pump <NUM> has a motor that operates at <NUM>/<NUM> and is not adjusted.

In the preferred embodiment, input tank liquid level <NUM> is below that of the output tank <NUM>, allowing the liquid mass <NUM> to be discharged from the output tank <NUM> over a wall <NUM> between the output tank <NUM> and the input tank <NUM>, thereby forming a weir <NUM>. Weir <NUM> has a wall <NUM> to separate liquid mass <NUM> between output tank <NUM> and input tank <NUM>. The weir <NUM> should be located just above upper manifold <NUM>, allowing the rotational flow to continue within the output tank <NUM>, while allowing liquid mass <NUM> to flow over weir <NUM> in a laminar fashion. In a preferred embodiment, the distance between liquid mass <NUM> level in the output tank <NUM> and the liquid level in input tank <NUM> may be between <NUM> inches and <NUM> inches.

Weir <NUM> provides both oxygenation and cooling to liquid mass <NUM>, which are essential functions in maintaining optimal conditions for support removal. The cooling effect of weir <NUM> allows temperature of liquid mass <NUM> to be controlled with much tighter tolerances, even at low temperature settings. Weir <NUM> therefore allows the user to process delicate parts <NUM> that would normally be in danger of being damaged or altered due to temperature overshoot. Wall <NUM>, which separates output tank <NUM> and input tank <NUM> to form weir <NUM> allows for simultaneous oxygenation, or aeration, and temperature reductions without the inclusion of additional costly or energy consuming features to regulate these parameters. Liquid mass <NUM> and weir <NUM> create a cascade to regulate oxygenation, pH and evaporation. Parameters of weir <NUM> have been optimized for efficiency of support removal.

As liquid mass <NUM> is consumed or exhausted through evaporation, mechanical, or chemical or other means, the consumed portion may require replacement. The level of liquid mass <NUM> in output tank <NUM> and input tank <NUM> is therefore monitored and maintained. As the liquid mass <NUM> is consumed, the liquid level of the input tank <NUM> decreases. Once the liquid mass <NUM> level in input tank <NUM> decreases to a certain point, a liquid level sensor <NUM>, which may be a continuous liquid level sensor, in input tank <NUM> is triggered, signaling the operator to replenish or restore liquid mass <NUM>. Unlike other support removal machines and systems, the support removal machine <NUM> of the present disclosure may not require the user to empty and refill the system completely, rather, the conditions of the liquid mass <NUM> are calibrated such that refilling the system when the level of liquid mass <NUM> is decreased to a set point may be sufficient to maintain operation of the system indefinitely.

Support removal machine <NUM> may respond automatically to changing conditions within output tank <NUM> and input tank <NUM>, and structural changes in the part <NUM>, while maintaining part <NUM> in an optimal location within output tank <NUM> for support removal. The continuous regulation of the position, circulation, and rotation of part <NUM> occurs in response to output tank <NUM> parameters, subject to a combination of parameters including liquid mass <NUM> flow, heat, ultrasound, and measurement capabilities, such that the use of energy in support removal machine <NUM> is maximized and damage to part <NUM> is minimized.

The flow of liquid mass <NUM>, generated as liquid mass <NUM> passes through a set of tank manifolds <NUM>, is generally rotational such that the liquid mass <NUM> is a vortex and that part <NUM> does not, due to the rotational flow of liquid mass <NUM>, generally contact the surface of liquid mass <NUM>. The position of manifolds <NUM> and the direction of the flow of liquid mass <NUM> generated from manifolds <NUM> creates a vortex that suspends part <NUM> between a surface of the liquid mass <NUM> and a bottom and sides of output tank <NUM>. In an alternative embodiment of the present disclosure, a single tank having a pump may generate flow to effectively rotate part <NUM> in a single chamber.

Referring now to <FIG>, manifolds <NUM> and nozzle orifices <NUM> are shown. The position of the manifolds <NUM> within output tank <NUM> is important in creating a circular flow of liquid mass <NUM>. <FIG> shows a continuous level sensor <NUM>, which floats to convey liquid mass level in input tank <NUM>. Sedimentation plate <NUM> is shown in <FIG>.

As shown in <FIG>, in a preferred embodiment, three manifolds <NUM> are positioned symmetrically around the output tank, where each manifold <NUM> is positioned along a different surface of output tank <NUM> at a junction between two sides of output tank <NUM>. Two manifolds <NUM> are positioned on opposite sides, a first and second side, of output tank <NUM> (as shown in <FIG> where nozzle orifices <NUM> are positioned at <NUM> degrees on manifolds adjacent opposite sides of output tank <NUM>). Adjacent manifolds <NUM> have a series of in-line nozzle orifices <NUM>, wherein nozzle orifices <NUM> are offset <NUM> degrees on each adjacent manifold <NUM>, such that the nozzle orifices <NUM> project liquid mass <NUM> parallel to adjacent sides, resulting in a rotational flow of liquid mass <NUM> in three directions at generally <NUM> degree angles along three sides of output tank <NUM>. This arrangement of manifolds <NUM> and orifice nozzles <NUM> induces a circular, rotational flow of liquid mass <NUM> and creates a vortex within the output tank <NUM>. Each manifold <NUM> may extend the entire width of output tank <NUM> and may contain a varied number of nozzle orifices <NUM> along manifold <NUM>, although embodiments may vary. In a preferred embodiment, the number of nozzle orifices <NUM>, each aligned in-line along manifold <NUM>, is five. The number of manifolds <NUM> may be important in order to create appropriate pressure on liquid mass <NUM> in order to produce appropriate rotational flow to maintain part <NUM> in a central location in output tank <NUM>. In a preferred embodiment, each manifold <NUM> is fed liquid mass <NUM> from the pump <NUM> with equal pressure from pump <NUM> through manifold inlet <NUM>, as shown in <FIG>. The apparatus and method of the present disclosure may not be limited to a particular number of tanks. Manifolds <NUM> may extend laterally along the junction between sides of output tank <NUM>.

Referring now to <FIG>, the manifolds are shown. The manifold <NUM> has a nozzle orifice <NUM>. The diameter of nozzle orifice <NUM> may vary depending on the desired conditions for optimizing liquid mass <NUM> pressure for support removal. Manifolds <NUM> and nozzle orifices <NUM> are positioned generally symmetrically around output tank <NUM> (as shown in <FIG>) and approximately at an edge along sides or side junctions of output tank <NUM> in order to propel liquid mass <NUM> in a plane with sides of output tank <NUM> such that a vortex is generated to maintain the position of the part <NUM> centrally within output tank <NUM> (see <FIG>). Table <NUM> shows how orifice size effects flow of liquid mass <NUM>.

Referring now to <FIG>, overflow tank drain <NUM> is shown. Sediment tank drain <NUM> is shown. Cleanout ports <NUM> are shown. The number of outlets for each purpose is not limiting.

Referring now to <FIG>, pump <NUM> and manifolds <NUM> are shown.

Referring now to <FIG>, a cross-sectional rear view shows mechanisms for pumping and filtering the liquid mass <NUM>. Filter <NUM> removes particulate matter generated during support removal as pieces of the support break apart. Pump <NUM> generates the pressure that forces the liquid through tank manifolds <NUM>. Pump <NUM> may be a commercially available pump, when used with the support removal machine <NUM> of the present disclosure, and would not require a custom build. The present disclosure is not limited to commercially available pumps. Pump <NUM> generates sufficient pressure, without the need for suction within the output tank <NUM>, to provide rotational flow such that the part is maintained in a centrally located position within output tank <NUM>. Ultrasonic generator <NUM>, or ultrasonic motor, supplies power for ultrasonic transducers, which may number between <NUM>-<NUM> without limitation.

Hydraulic pressure oscillates and suspends a 3D printed part while interrogating with ultrasonic frequencies. A key functional feature of the present disclosure is the ability to maintain the position of the part <NUM> in a generally central location in output tank <NUM>. Maintaining position of part <NUM> is accomplished through the use of manifolds <NUM> positioned at locations throughout tank <NUM> to create a rotational liquid flow, or vortex, that creates liquid current to sinks a part <NUM> that would otherwise float and to float a part <NUM> that would otherwise sink. Under the rotational flow conditions generated by the apparatus and method of the present disclosure, a part <NUM> is centrally located, submerged in a tank and circulated around a central axis of the tank, along with being rotating around an axis of the part <NUM>. In one embodiment, one or more manifolds may be positioned on the walls of the tank at certain locations along output tank <NUM> including one position immediately adjacent to weir <NUM> on wall <NUM>. The location of pump <NUM>, connected to the manifolds <NUM>, allows for the use of commercially available pumps, rather than custom built pumps, because the manifolds were designed around the performance, or operating abilities, of the pumps. However, custom built pumps are contemplated within the present disclosure.

Rotation of part <NUM> within the liquid mass <NUM> creates friction between the materials in the liquid mass <NUM> and the part <NUM>, resulting in support removal. In one embodiment, support removal is enhanced by ultrasonic transducers <NUM> placed tangentially in output tank <NUM> with respect to rotating part <NUM>. Ultrasonic generator <NUM> creates heat in liquid mass <NUM> within output tank <NUM>, which causes support removal through multiple direct and indirect means, while also causing cavitation through direct interaction with the rotating part <NUM>. As the part <NUM> spins within the liquid mass <NUM>, each aspect of part <NUM> is exposed to ultrasound, thereby creating a synergistic effect in support removal through rotational effects in liquid mass <NUM> and the ultrasonic enhancement of support removal.

Referring now to <FIG>, a cross-sectional side view shows the flow of liquid mass <NUM> during pumping by pump <NUM>, as indicated by the curved arrows in output tank <NUM>, along with the concomitant rotation of 3D printed part <NUM>. As illustrated in <FIG>, as 3D printed part <NUM> rotates in the center of output tank <NUM>, different surfaces of 3D part <NUM> are exposed to tangential radiation from ultrasonic transducer <NUM>. Ultrasonic transducer <NUM> interrogates part <NUM> as part <NUM> rotates in output tank <NUM>. Part <NUM> may be tangential to ultrasonic transducer <NUM>, and rotation of part <NUM> allows all aspects of the part <NUM> to be exposed to ultrasound. Part <NUM> generally circulates around a central point in output tank <NUM>, and part <NUM> rotates. The motion of part <NUM> in output tank <NUM> creates a controlled agitation. The action of part <NUM> during this process therefore creates support removal through friction by continuous rotational motion of 3D printed part <NUM> within the detergent, along with a uniform interrogation from ultrasonic transducer <NUM>, thereby generating synergy in support removal between the action of the pump, the heater, the chemistry and the ultrasonic transducer.

The ultrasonic interrogation of part <NUM> creates heat and cavitation in a generally uniform manner across the part as it rotates and circulates through output tank <NUM>, exposing each surface of part <NUM> to the ultrasound. Additionally, a heating unit may also be used to generate heat for enhancing support removal. The heating unit and the ultrasonic generator <NUM> may operate in harmony, such that when the ultrasonic generator <NUM> needs to be dialed down, the heating unit can compensate by maintaining the heat of the mass at an optimal level. A heating unit may be positioned wherein said heating means comprises a heating element having an internal end positioned internally in the output chamber <NUM> to engage the liquid mass and an external end communicatively coupled to said microprocessor for controlling heat input to the liquid mass contained within the output chamber <NUM>. An advantage provided by the use of ultrasound is the creation of cavitation of liquid mass <NUM>, which a heater and pump <NUM> may not do. Overuse of the ultrasonic transducer <NUM> may degrade the liquid mass <NUM> such that liquid mass <NUM> becomes exhausted. The part40 material may be energy sensitive to deforming or delaminating such that constant optimization of energy within the system is important.

The use of an ultrasonic transducer <NUM> has dual effects, such that the ultrasonic transducer <NUM> may be considered a mixing component for liquid mass <NUM> rather than an just a heater. While heating with an ultrasonic transducer <NUM> may require more energy than the use of a standard heating unit, the ultrasonic transducer <NUM> has multiple effects. Ultrasound affects the surface of part <NUM> microscopically by causing vibration, thus, the work being done by ultrasonic transducer <NUM> extends beyond heating alone, thus creating a synergistic effect for support removal, and increasing efficiency of the process.

It is obvious that the components comprising the support removal apparatus may be fabricated from a variety of materials, providing such selection or use of materials possess the capacity to withstand premature corrosion given the presence and use of an alkaline aqueous cleaning solution, notably falling within a variety of pH ranges. The tank can be made of <NUM> and/or <NUM> SS or any steel alloy with better corrosion resistance than <NUM> SS. Accordingly, it is most desirable, and therefore preferred, to construct the output tank and input tank work surface, top and nozzle heads from stainless steel; pipe and fittings from a polymeric material such as polyamide (PA) or acrylonitrile-butadiene-styrene (ABS); and cabinet and storage cabinet from a lower grade stainless steel. It is noted herein that the retention tank, nozzle head, work surface, and integral work platform may be alternatively fabricated from materials to lessen the overall weight of the support removal apparatus yet maintaining sufficient resistance to corrosion, such as polypropylene, polyoxymethylene, polyphenylene, ABS, or PA. Similarly, the pump, thermocouple, heating element <NUM>, and level indicator, particularly exposed operable components of each, are fabricated from a high grade stainless steel or coated with an impervious, corrosive-resistant material such as epoxy.

Claim 1:
A method of removing support material, comprising:
providing a part-containing tank (<NUM>);
filling the part-containing tank with a liquid mass (<NUM>);
generating a vortex in the liquid mass (<NUM>) contained in the part-containing tank (<NUM>);
placing a part (<NUM>) having support material in the liquid mass (<NUM>) in the part-containing tank (<NUM>);
suspending the part in the liquid mass (<NUM>) within the vortex; and
removing support material from the part (<NUM>), wherein the part-containing tank (<NUM>) has a first side (<NUM>), a second side and a bottom surface; wherein the first side (<NUM>) is opposite the second side; characterised in that a first manifold (<NUM>) is positioned at a top portion of the first side (<NUM>) and is configured to direct a downward flow of the liquid mass (<NUM>) along the first side (<NUM>); wherein a second manifold (<NUM>) is proximal to a junction between the first side (<NUM>) and the bottom surface and is configured to direct a lateral flow of the liquid mass (<NUM>) along the bottom surface toward the second side.