Gel-like Support Material for Additive Manufacturing
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Solution Overview
Problem
Existing 3D printing methods face challenges in printing complex shapes with overhangs and cavities due to the lack of effective support materials that can prevent distortion and collapse, and are often limited by high temperature requirements or solvent use, leading to issues like shrinkage and difficulty in removing supports.
Innovation Solution
A gel-like support material composed of an organic compound with secondary hydroxyl groups, nanoclay, water, and a water-soluble polymer, which exhibits thixotropic properties, allowing for the printing of complex shapes without distortion and can be easily removed or recycled.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional support materials are used to print complex shapes with overhangs, then the structural integrity is improved, but the temperature requirements become excessively high or solvent use is required
Solution Approach 1:
The support material undergoes parameter changes in its physical state - transitioning from a gel-like state during printing to a soluble state for removal. The composition includes water-soluble polymers and nanoclays that maintain structural integrity during printing at moderate temperatures, then enable easy removal through water dissolution, eliminating the need for high temperature processing
Solution Approach 2:
The invention uses a composite support material system combining water-soluble polymers, nanoclays, and other functional components. This composite formulation provides both the mechanical strength needed for structural support during printing and the solubility required for easy removal, resolving the contradiction between strength and temperature requirements
2Manufacturing precision
If conventional support materials are used to prevent distortion and collapse, then the manufacturing precision is improved, but the support removal becomes difficult
Solution Approach 1:
The support material is designed to be easily discarded through water dissolution after serving its purpose. The water-soluble polymer components allow for simple removal by immersing the printed object in water, making the support removal process as easy as pouring water over the structure, thus resolving the contradiction between maintaining precision during printing and ease of removal afterward
3Stability of the object's composition
If conventional support materials are used during long printing processes, then the stability is improved, but shrinkage of the printed material is observed
Solution Approach 1:
The gel-like support material acts as an intermediary substance that provides stable support during the printing process without causing shrinkage. Its unique composition with nanoclays and water-soluble polymers creates a stable matrix that maintains the printed structure's dimensions while allowing easy removal, thus resolving the contradiction between stability during printing and shrinkage prevention
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
Enables the successful printing of complex three-dimensional articles with minimal shrinkage and easy support removal, maintaining the integrity of the printed structure and allowing for the reuse of the support material.
Implementation Method 1
A gel-like support material composed of an organic compound with secondary hydroxyl groups, nanoclay, water, and a water-soluble polymer, which exhibits thixotropic properties
Data Source
AI summary
The invention relates to a method for the additive manufacturing of a cured elastomer article. In particular, the invention relates to a method for the additive manufacturing of a 3-dimensional cured material and a support using a 3D printer.