3D Printing Support Structure with Breakable Release Agent

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Solution Overview

Problem

In 3D printing, sections of patterned intermediate parts without direct support during patterning and sintering can deform, leading to unusable or aesthetically unpleasing final parts due to lack of support.

Innovation Solution

A build material support structure is created and temporarily bound to the patterned intermediate part using a patterned breakable connection with a release agent containing white colorant and boehmite particles, providing support during sintering and allowing easy removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a build material support structure is created to prevent deformation during sintering, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:

Improvedimensional accuracy of patterned intermediate partVSAvoidcomplexity of support structure and binding process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

A build material support structure is introduced as an intermediary element to support sections of the patterned intermediate part that lack direct support during patterning and sintering. This support structure prevents deformation and maintains dimensional accuracy, while being temporarily bound through patterned breakable connections that allow easy removal after serving its protective function.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The support structure is designed as a temporary, disposable element that is discarded after fulfilling its support function. The patterned breakable connections enable easy separation and removal of the support structure from the final part, eliminating the need for complex permanent support mechanisms and reducing overall device complexity.

Inventive Principle:

Principle #34Discarding and recovering

2Ease of operation

If a release agent with white colorant and boehmite particles is used to create patterned breakable connections, then ease of operation is improved, but loss of substance increases

Engineering Contradiction:

Improveease of support structure removalVSAvoidconsumption of release agent materials

Core Design Contradiction:

Ease of operationVSLoss of substance

Solution Approach 1:

The release agent incorporates white colorant that provides visual indication of where breakable connections have been formed. This color change mechanism allows operators to easily identify and target specific areas for support structure removal, significantly improving ease of operation and reducing time and effort required for the separation process.

Inventive Principle:

Principle #32Color changes

Solution Approach 2:

The release agent is formulated as a composite material containing white colorant, boehmite particles, and binding agents. This composite structure provides multiple functions: the colorant for visual guidance, the boehmite particles for creating weak breakable bonds, and the binding agents for temporary adhesion. The composite nature allows efficient material usage while achieving easy removal.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution ensures the formation of a stable 3D object by preventing deformation during sintering and enabling easy separation of the support structure, resulting in a usable and aesthetically pleasing final product.

Implementation Method 1

The liquid functional agent is capable of penetrating the layer of build material onto which it is applied, and spreading onto the exterior surface of the build material particles of that layer

Methodology Applied

Scientific EffectPenetration and spreading: Capillary Action

Implementation Method 2

The liquid functional agent may include a binder that holds the build material particles of the patterned intermediate part together

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 3

The patterned intermediate part may then be exposed to heat to sinter the build material in the patterned intermediate part to form the 3D object/part

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 4

a build material support structure is built as the patterned intermediate part is built, which provides support to the patterned intermediate part during patterning

Methodology Applied

Scientific EffectMechanical support:

Implementation Method 5

the build material support structure is temporarily bound to the patterned intermediate part at a patterned breakable connection

Methodology Applied

Scientific EffectTemporary binding:

Data Source

PatentUS11479682B2Three-dimensional printing

Publication Date: 2022.10.25 PERIDOT PRINT LLC

AI summary

In an example, a three-dimensional (3D) printing kit includes a metallic build material composition; a binding agent; and a release agent for patterning a breakable connection. The binding agent includes a first latex binder. The release agent includes a white colorant including a white metal oxide pigment coated with a coating selected from the group consisting of alumina, silica, and combinations thereof; boehmite particles; a second latex binder; and an aqueous vehicle.