3D Printing Support Material Removal Using Bipolar Surfactant

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Solution Overview

Problem

In the laminate shaping method, the removal of support material from complex three-dimensional objects, such as overhang structures, is challenging due to the softening of water-soluble organic materials at lower temperatures than structural materials, leading to shape deviations and difficulties in achieving high shape and dimensional accuracy.

Innovation Solution

The use of water-insoluble structural material particles and support material particles containing a water-soluble material and fiber material, which are laminated and then removed using a liquid containing water and a bipolar surfactant, allowing for improved removal performance without deforming the support portion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If water-soluble organic material is used as support material, then the support portion can be removed by washing with water, but the support material softens at lower temperatures than structural material leading to shape deviations

Engineering Contradiction:

Improveease of removalVSAvoidshape accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The support material is designed as a composite consisting of water-soluble material and fiber material. The fiber material provides structural integrity and maintains shape at lamination temperatures, while the water-soluble material enables removal by washing. This composite structure resolves the contradiction between ease of removal and shape accuracy during manufacturing.

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If water-soluble material is used as support material, then removal is facilitated, but the support material deforms during lamination due to softening

Engineering Contradiction:

Improveease of removalVSAvoidshape stability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The composite support material combines fiber material (providing thermal stability and shape maintenance) with water-soluble material (providing removal capability). The fiber component prevents deformation during lamination while the water-soluble component enables easy removal afterward, resolving the contradiction between operational ease and compositional stability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention changes the temperature parameter relationship between support and structural materials. The composite support material maintains stability at lamination temperatures (withstanding heat without deforming) while being removable at ambient temperatures through water washing, effectively decoupling the temperature requirements for stability and removal.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If conventional support material is used, then complex structures can be supported, but removal causes surface damage to the shaped portion

Engineering Contradiction:

Improvesupport capabilityVSAvoidsurface damage

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The invention changes the chemical parameter of the removal process by using water-soluble material that dissolves in water. This allows removal through gentle washing rather than mechanical means, eliminating surface damage while maintaining the support material's ability to uphold complex structures during manufacturing.

Inventive Principle:

Principle #35Parameter changes

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

This approach enables the production of three-dimensional objects with high shape and dimensional accuracy by maintaining the shape integrity of support material particles during lamination and facilitating easy removal with a water-based solution, reducing environmental impact and production costs.

Implementation Method 1

a liquid containing water and a bipolar surfactant

Methodology Applied

Scientific EffectSurfactant: Surfactant

Implementation Method 2

bringing a portion of the shaped object including the support material into contact with a liquid containing water and a bipolar surfactant to remove the portion

Methodology Applied

Scientific EffectWetting: Wetting

Data Source

PatentUS10532383B2Method of producing three-dimensional object and removing liquid to be used in the production method

Publication Date: 2020.01.14 CANON KK

AI summary

Provided is a method of producing a three-dimensional object, including: a first step of placing and laminating a water-insoluble structural material and a support material each containing a water-soluble material and a fiber material to form a material layer; and a second step of bringing a portion of the shaped object including the support material into contact with a liquid containing water and a bipolar surfactant to remove the portion.