Low-Modulus 3D Article Support With Breakaway Sheath Strands

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Solution Overview

Problem

Challenges exist in forming 3D articles from fragile, low modulus materials such as hydrogels, as they are prone to damage during fabrication, post-processing, shipping, and handling.

Innovation Solution

A method involving a conformal sheath with connecting strands is used to support the 3D article, allowing easy peeling of the sheath without damaging the delicate structure, utilizing a photocurable liquid ink that hardens in response to UV, violet, and blue radiation, and includes a support structure with a gap filled with photocurable liquid ink.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional support structure is used for low modulus articles, then the article is supported during fabrication, but the article is damaged during removal from the liquid tank

Engineering Contradiction:

Improvearticle integrityVSAvoidremoval process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The support structure is segmented into multiple discrete strands rather than a continuous rigid support. These strands are distributed throughout the article and can independently break or deform during removal, preventing damage to the fragile low modulus article while still providing support during fabrication.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support structure uses materials with significantly different mechanical properties than the low modulus article. The strands are designed to be more rigid than the hydrogel article, allowing them to maintain structural integrity during fabrication but be easily separated during removal without damaging the delicate article.

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If a rigid support structure is used, then the article is stable during fabrication, but the structure is difficult to remove without damaging the article

Engineering Contradiction:

Improvestructural stabilityVSAvoidsheath removal

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The support structure is divided into multiple thin strands that can be individually broken or peeled away. This segmentation allows the structure to provide stable support during fabrication but enables easy removal by simply breaking the thin strands, which requires minimal force and does not damage the fragile article.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support strands are designed as disposable elements that are intentionally made to be easily broken or removed after serving their support function. Once the article is fabricated and removed from the liquid tank, the strands can be easily discarded by breaking them, eliminating the need for complex removal mechanisms.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If the sheath is tightly coupled to the article for support, then the article is protected, but the peeling process becomes difficult and may damage the article

Engineering Contradiction:

Improvearticle protectionVSAvoidpeeling ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The coupling between the sheath and article is segmented into discrete strand connections rather than a continuous tight coupling. This allows the sheath to provide protection during fabrication while enabling easy peeling by simply breaking the individual strand connections, which requires minimal force and does not damage the article.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support structure is designed with predetermined weak points or break zones in the strands that allow for easy separation. This beforehand design ensures that when peeling is needed, the strands break at predetermined locations rather than requiring force that could damage the fragile low modulus article.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 method effectively supports and protects fragile 3D articles during manufacturing and removal from the liquid tank, ensuring minimal damage and facilitating easy handling and transport.

Implementation Method 1

The photocurable liquid ink hardens in response to exposure to ultraviolet (UV), violet, and/or blue radiation

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS12447689B2Method for manufacturing low modulus articles

Publication Date: 2025.10.21 LUNG BIOTECH PBC

AI summary

A method of manufacturing a three-dimensional (3D) article includes operating a print engine to fabricate a composite structure including the 3D article coupled to a support structure, removing the composite structure from the fluid tank, and peeling the inside surface of the sheath away from the outer surface of the article, peeling progressively breaks the plurality of strands. The support structure includes a conformal sheath having an inside surface that follows the outer surface of the 3D article with a gap between the inside surface of the sheath and the outer surface of the article, and a plurality of strands that span the gap and individually have opposed ends that are coupled to the inside surface of the sheath and the outer surface of the article to maintain the gap, the gap filled with the photocurable liquid ink.