Flexible Sacrificial Structure for Additive Manufacturing
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Solution Overview
Problem
Current additive manufacturing methods face challenges in efficiently removing sacrificial support structures from complex geometries like denture models, which often require laborious post-processing steps to achieve consistent surface textures and avoid damage.
Innovation Solution
A method involving a flexible sacrificial structure composed of interlaced modeling and support materials, with a flexible overlay and intermediate support layer, allows for easy separation of objects by pressure application, enabling efficient removal and minimizing post-processing needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional support structures are used in additive manufacturing, then objects with complex geometries can be fabricated, but the removal of support structures requires laborious post-processing steps
Solution Approach 1:
The support structure is divided into multiple segments including an intermediate support layer and an outer flexible overlay. This segmentation allows the outer overlay to be easily peeled away while the intermediate layer remains attached to the object, significantly reducing post-processing time and effort.
Solution Approach 2:
An intermediate support layer is introduced between the object and the outer flexible overlay. This intermediate layer acts as a mediator that stays attached to the object during removal, allowing the outer overlay to be easily separated without directly contacting and damaging the object surface.
2Strength
If traditional support structures are used, then structural support during printing is provided, but surface texture consistency is compromised
Solution Approach 1:
Different layers of the support structure have different properties optimized for their specific functions. The outer flexible overlay provides easy removal and surface protection, while the intermediate layer provides structural support and maintains surface texture consistency by remaining attached to the object during printing and removal.
Solution Approach 2:
The outer flexible overlay is designed as a thin, flexible shell that can be easily peeled away from the object. This flexible shell protects the object surface during printing and removal, ensuring consistent surface texture while allowing easy separation after fabrication.
3Ease of operation
If flexible sacrificial structure with intermediate layer is used, then easy removal is achieved, but device complexity increases
Solution Approach 1:
The support structure incorporates a flexible outer overlay that can dynamically deform and peel away from the object during removal. This dynamic flexibility simplifies the removal operation despite the multi-layer complexity, as the flexible overlay adapts to the object shape and separates easily without requiring complex tools or procedures.
Data Source
AI summary
A method of additive manufacturing of three-dimensional objects by sequentially dispensing and solidifying layers. The layers may include (i) stacks of model layers arranged in configured patterns corresponding to shapes of one or more objects and being made of one or more modeling materials; (ii) an intermediate layer surrounding said shapes of one or more objects and comprising at least a support material, and (iii) a flexible overlay surrounding said first intermediate layer, the intermediate layer and flexible overlay forming a flexible sacrificial structure. The model stack or stacks can be removed from the flexible sacrificial structure by application of pressure to the flexible sacrificial structure, separating the model stack from the flexible structure along the intermediate layer.