Hybrid Support Material for Additive Manufacturing
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Solution Overview
Problem
Current sacrificial support materials in additive manufacturing, such as multi-jet modeling, face challenges with high temperature requirements for removal, warpage, and inefficient post-processing due to phase separation and poor adhesion, leading to issues like trough formation and warping.
Innovation Solution
A hybrid support material comprising C12 to C18 fatty alcohol ethoxylate and C16 to C22 fatty alcohol with a tackifier, allowing for a transition temperature below 65°C for efficient melting and washing, enhancing adhesion and wettability while maintaining jettable properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pure melting support material is used, then support removal is achieved, but high temperatures are required which lead to warpage of cured build materials
Solution Approach 1:
The patent combines two support material types into a hybrid formulation: melt-away material (for easy removal) and wash-away material (for low-temperature removal). This merging allows the support material to be removed at lower temperatures without requiring high heat that would cause warpage, while still maintaining ease of removal through the combined mechanisms of melting and washing.
Solution Approach 2:
The invention uses a composite support material system comprising both meltable and washable components. This composite approach enables the support material to leverage the advantages of both types: the meltable portion provides easy removal while the washable portion allows low-temperature processing, preventing warpage of the build material.
2Temperature
If pure washable support material is used, then low temperature removal is achieved, but water-jet mechanical removal becomes time-consuming and can break delicate build parts
Solution Approach 1:
The patent merges wash-away and melt-away material types to create a hybrid support system. The melt-away component enables thermal removal at moderate temperatures without requiring prolonged water-jet mechanical processing, thus reducing post-processing time while avoiding damage to delicate build parts. The washable component still provides low-temperature removal capability.
3Stability of the object's composition
If support material has high adhesion to prevent trough formation, then build/support interface integrity is improved, but warping and delamination occur upon cooling
Solution Approach 1:
The patent applies local quality by having different regions of the support material exhibit different adhesion characteristics. The formulation includes components that provide strong adhesion at the build/support interface to prevent trough formation, while other components are designed to delaminate cleanly from the substrate upon cooling. This localized differentiation of material properties allows simultaneous achievement of interface integrity and warping 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
The hybrid support material enables fast and complete removal with reduced post-processing time, minimizing warping and trough formation, and improving the structural integrity of 3D printed articles.
Implementation Method 1
a transition temperature measured as the temperature immediately before phase change, based on viscosity measurement, is less than about 65° C.
Implementation Method 2
Both materials' design sets have their limitations. Pure melting materials can oftentimes require high temperatures for removal
Implementation Method 3
a tackifier, wherein a transition temperature measured as the temperature immediately before phase change, based on viscosity measurement, is less than about 65° C.
Data Source
AI summary
A support material for use in additive manufacturing includes greater than about 30 weight percent up to about 70 weight percent of a C12 to C18 fatty alcohol ethoxylate, about 30 weight percent to about 70 weight percent of a C16 to C22 fatty alcohol, and a tackifier, a transition temperature measured as the temperature immediately before phase change, based on viscosity measurement, is less than about 65° C. A system for additive manufacturing includes such a support material and a build material, the ratio of C12 to C18 fatty alcohol ethoxylate to C16 to C22 fatty alcohol is selected for property matching of the support material to the build material. A method of additive manufacturing includes providing such a system and printing via an inkjet printer the support material and the build material to provide a precursor to a three-dimensional printed article.