Additive Manufacturing Support Materials for Hollow Structures
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Solution Overview
Problem
Current additive manufacturing methods face challenges in efficiently and safely removing support materials from intricate geometries, such as hollow structures, due to the use of gel-like materials that are difficult to access and can damage the object during removal.
Innovation Solution
The use of non-curable liquid materials that remain flowable under mild conditions, allowing for easy removal by pressure, and can be combined with gel-like support materials for enhanced accessibility and object safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If gel-like support materials are used in additive manufacturing, then the support structures can provide adequate mechanical strength and stability during printing, but the support materials become difficult to remove from intricate geometries and may damage the object during removal
Solution Approach 1:
The invention divides the support material into two distinct functional components: a curable component that provides mechanical strength and stability during printing, and a removable component that facilitates easy removal after printing. This segmentation allows each component to independently fulfill its specific function without compromising the other.
Solution Approach 2:
The invention utilizes parameter changes by selecting a removable component with specific properties (low glass transition temperature, low melting point, or water solubility) that allow it to change state under mild conditions. This enables the support material to transition from a rigid, strength-providing state during printing to a flowable or soluble state for easy removal.
2Loss of substance
If aggressive removal methods are used to remove support materials from complex geometries, then complete removal can be achieved, but the object may be damaged in the process
Solution Approach 1:
The removable component is specifically selected to undergo parameter changes (phase transition or dissolution) under mild conditions such as low temperature, atmospheric pressure, or contact with water. This allows complete support material removal from complex geometries without requiring aggressive mechanical or chemical methods that could damage the printed object.
Solution Approach 2:
The invention replaces aggressive mechanical removal methods with gentler removal mechanisms based on phase transitions (melting, softening) or chemical dissolution. This substitution eliminates the need for forceful mechanical actions that could damage intricate object geometries while ensuring complete support material removal.
3Ease of operation
If liquid materials are used in additive manufacturing, then the materials are easy to dispense and remove, but they cannot provide adequate structural support during the printing process
Solution Approach 1:
The invention merges two materials with complementary properties into a single support material composition: a curable component that provides structural strength and stability during printing, and a removable component that enables easy removal after printing. The combination allows the support material to exhibit both structural integrity during the printing process and ease of removal afterward.
Solution Approach 2:
The removable component in the combined support material is selected to undergo parameter changes (phase transition or dissolution) under mild conditions. This allows the material to maintain structural properties during printing when the curable component is active, then transition to a flowable or soluble state for easy removal, thus achieving both ease of operation and adequate strength at different stages.
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 facilitates the efficient removal of support materials from complex geometries without damaging the object, reducing the need for aggressive removal methods and improving the ease of use and environmental safety in additive manufacturing.
Implementation Method 1
The liquid material features a non-crystalline nature, which is attributable to a specific formulation and/or a specific manufacturing process that may include suppression of crystallization
Implementation Method 2
exposing the dispensed building material formulations to the curing condition, to thereby form the first hardened modeling material
Data Source
Figure 1A~1B
Figure 2
Figure 3~4A
AI summary
Method of additive manufacturing of a three-dimensional object employing building material formulations that provide, upon exposure to a curing condition, liquid or liquid-like material, and three-dimensional objects obtainable thereby are provided. The methods are usable for fabricating objects featuring one or more hollow structures.