3D Printing Support Material for High-Temperature Water Removal

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Solution Overview

Problem

Current support materials in additive manufacturing are inadequate for high-temperature part materials, as they often soften or deform under processing conditions, and existing water-soluble polymers are limited, making it difficult to efficiently remove support structures from 3D printed parts, especially when creating hollow structures or parts with complex geometries.

Innovation Solution

A semi-crystalline polyamide support material with a melting temperature of at least 250°C and enhanced water absorption behavior is used, allowing for effective swelling and detachment from high-temperature engineering plastics, facilitated by incorporating a water-soluble polymeric additive for easy removal via moisture exposure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional support materials are used for high-temperature part materials, then the support structures can provide mechanical support during printing, but they soften or deform under processing conditions

Engineering Contradiction:

Improveprocessing temperatureVSAvoidsupport structure stability

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent changes the thermal parameters of the support material by selecting semi-crystalline polyamides with melting temperatures of at least 250°C, which maintains structural stability during high-temperature printing processes while enabling controlled removal through water absorption

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The support material is formulated as a composite system combining semi-crystalline polyamides with specific water absorption characteristics, creating a material that exhibits both high-temperature stability and controlled solubility for easy removal

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If water-soluble polymers are used as support materials, then support structures can be easily removed through soaking and rinsing, but the available polymer options are limited and removal efficiency is insufficient

Engineering Contradiction:

Improvesupport structure removalVSAvoidremoval efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent modifies the water absorption parameters of the polyamide support material to optimize removal efficiency, selecting materials with specific water uptake characteristics that enable rapid and complete dissolution during post-processing

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The support material exhibits different properties in different conditions: high thermal stability during printing, then high water solubility during removal, allowing the same material to fulfill opposing requirements at different stages

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If support structures are used for complex geometries and hollow structures, then printing feasibility is improved, but removal of support materials becomes difficult and time-consuming

Engineering Contradiction:

Improveprinting feasibilityVSAvoidpost-processing time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The support material undergoes a phase transition from a solid, structurally stable state during printing to a dissolved state in water, enabling complete removal from complex geometries without mechanical intervention

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The patent replaces mechanical removal methods (manual extraction, cutting) with a chemical dissolution process, where water acts as a solvent to automatically remove support structures from complex and hollow geometries

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution enables the successful printing of high-temperature part materials by providing robust support structures that can be easily detached from the final 3D object, maintaining structural integrity and simplifying the post-processing removal of support materials, even for complex geometries.

Implementation Method 1

A semi-crystalline polyamide support material with a melting temperature of at least 250°C and enhanced water absorption behavior is used

Methodology Applied

Scientific EffectWater absorption: Absorption (physical)

Implementation Method 2

incorporating a water-soluble polymeric additive for easy removal via moisture exposure

Methodology Applied

Scientific EffectWater solubility: Solvation

Data Source

PatentEP3436503B2Method for manufacturing a three-dimensional object

Publication Date: 2023.10.25 SOLVAY SPECIALTY POLYMERS USA LLC

AI summary

The invention pertains to a method for manufacturing a three-dimensional object with an additive manufacturing system, such as an extrusion-based additive manufacturing system, a selective laser sintering system, and/or an electrophotography-based additive manufacturing system, comprising providing a support material comprising more than 50 % wt. of a semi-crystalline polyamide [polyamide (A)] having a melting point, as determined according to ASTM D3418, of at least 250°C and possessing a water absorption at saturation, by immersion in water at 23°C, of at least 2 % wt.