Consumable Scaffold for 3D Printing Adhesion Control

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Solution Overview

Problem

3D printing processes face challenges in detaching objects from build plates without damage due to unwanted adhesion, as non-stick surfaces are either ineffective for molten materials or advantageous for solidified ones, and there is a lack of materials that adhere to molten thermoplastic but not to cured thermoplastic.

Innovation Solution

The use of a consumable scaffold mechanically attached to the build plate, made of the same thermoplastic as the filament, with tailored geometry and adhesion properties to support molten filament deposition and facilitate easy detachment of the object without damaging it.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a non-stick surface is applied to the build plate, then cured and solidified objects can be easily detached, but molten material cannot adhere properly during deposition

Engineering Contradiction:

Improvedetachment of cured objectVSAvoidadhesion of molten material

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The build plate surface is segmented into two functional zones: a non-stick base surface for easy detachment, and a consumable scaffold with adhesive properties for reliable molten material deposition. This segmentation allows each zone to perform its specialized function without compromise.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The consumable scaffold acts as an intermediary between the non-stick build plate and the molten thermoplastic filament. It provides the necessary adhesion for filament deposition while being mechanically attachable to the build plate, resolving the contradiction between non-stick detachment and sticky deposition.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a material is used that adheres to molten thermoplastic, then filament deposition is successful, but the cured object cannot be detached without damage

Engineering Contradiction:

Improveadhesion of molten materialVSAvoiddetachment of cured object

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The system segments the adhesion function: the consumable scaffold provides strong adhesion for molten filament, while the build plate itself remains non-stick for easy final detachment. The scaffold is positioned between the build plate and molten material, providing localized adhesion only where needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The consumable scaffold is designed as a disposable component that is attached to the build plate, used for filament deposition, and then removed. It sacrifices itself to provide the necessary adhesion during printing, while the build plate itself remains undamaged and reusable.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Strength

If straight segments of filament are deposited under tension, then high-tensile-strength materials can be manufactured, but the build plate must provide opposing drag force through adhesion

Engineering Contradiction:

Improvetensile strength of filamentVSAvoidadhesion between build plate and molten filament

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The consumable scaffold serves as an intermediary that provides the necessary drag force for filament tension. It is mechanically attached to the build plate and provides localized adhesion exactly where the molten filament contacts it, enabling tension-based deposition without requiring the entire build plate to be adhesive.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Adhesion is applied locally only at the consumable scaffold contact points rather than across the entire build plate surface. This localized adhesion is sufficient to provide the drag force needed for filament tension while maintaining non-stick properties elsewhere on the build plate.

Inventive Principle:

Principle #3Local quality

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 method allows for precise control of adhesion and support for complex geometries, enabling the deposition of filament under tension and easy removal of the object without damaging it, while the consumable scaffold can be recycled or discarded.

Implementation Method 1

adhesion between the molten material being deposited and the build plate is advantageous

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

the consumable scaffold and the object—which are fused together at the distal ends of the pillars

Methodology Applied

Scientific EffectHeating and melting: Heating

Implementation Method 3

a base sheet and an array of pillars that are cantilevered from one side of the base sheet

Methodology Applied

Scientific EffectMechanical support through cantilevered structure:

Data Source

PatentUS10538035B2Consumable scaffold for 3D printing of high-tensile-strength materials

Publication Date: 2020.01.21 STRATASYS INC

AI summary

A consumable scaffold and technique for supporting an object while it is being manufactured is disclosed. The consumable scaffold comprises a base sheet and an array of pillars that are cantilevered from one side of the sheet. The consumable scaffold resembles a bed of nails. Each pillar in the array of pillars is trimmed to a desired length and the object is manufactured by fusing thermoplastic filaments to the tips of the pillars.