3D Print Support Geometry for Sag-Free Hollow Cover Structures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing support geometries for three-dimensional objects made of plasticizable and/or solidifiable mass often result in sagging during manufacturing, requiring extensive material use and prolonged construction times, especially when bridging large distances without support structures.
Innovation Solution
A lightweight support geometry is designed with a combination of support planes and widening planes, where drops and/or strands are arranged in specific configurations to prevent sagging, including one-dimensional rows, clusters, and grid-like arrangements, using materials that can be easily removable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If full-volume support structures are used to prevent sagging, then stability and support effectiveness are improved, but material usage and construction time increase significantly
Solution Approach 1:
The support structure is segmented into discrete droplets arranged in specific patterns (one-dimensional rows, two-dimensional clusters, three-dimensional grid-like arrangements) rather than using continuous full-volume support. This segmentation allows the support function to be achieved with minimal material while maintaining stability during manufacturing.
Solution Approach 2:
Droplets are strategically positioned at critical locations where support is needed to prevent sagging, rather than providing uniform support throughout the entire volume. The droplet arrangement adapts to local geometric requirements, placing support elements where they are most effective for bridging cavities and supporting overhangs.
2Ease of operation
If water-soluble support material is used to enable easy removal, then ease of operation is improved, but dissolution time increases due to high density
Solution Approach 1:
The support structure uses water-soluble material that is intended to be temporary and easily removed after manufacturing. The material is chosen for its removability properties, accepting that dissolution time is a necessary trade-off for achieving clean, non-destructive separation of the support from the manufactured object.
3Loss of substance
If bridging technique is used to reduce support structures, then material usage is reduced, but bridging capability is limited to certain distances
Solution Approach 1:
The support approach transitions from traditional one-dimensional bridging to multi-dimensional droplet arrangements. By organizing droplets in one-dimensional rows, two-dimensional clusters, and three-dimensional grid-like patterns, the support structure can span longer distances and provide more comprehensive support while using less material than full-volume approaches.
Data Source
Figure 1~3
Figure 4~6
AI summary
The invention relates to support geometry (1) for producing a three-dimensional object (5) from a plasticisable and/or solidifiable substance, which object has at least one planar covering structure (7) over at least one hollow chamber, the support geometry comprising at least one carrier structure (2), which extends from an object carrier (6) or a planar bottom structure (8) of the three-dimensional object (5) through the at least one hollow chamber to the planar covering structure (7), wherein the support geometry (1) is made of the same or a different droplet-shaped or strand-shaped plasticisable and solidifiable substance as the three-dimensional object (5), and wherein the carrier structures (2) consist of droplets and/or strands and are produced such that sagging of the cover structure (7) resting thereon is prevented.