Multi-Material 3D Printing With Removable Support Transitions
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Solution Overview
Problem
Existing three-dimensional rapid prototyping methods struggle to accurately manufacture objects using multiple solidifiable materials, as they often cannot accommodate the use of different materials effectively, leading to difficulties in building objects with removable supports without damaging the finished product.
Innovation Solution
A system and method that utilize multiple solidifiable material sources, where one material is used for object construction and another for removable supports, with a pattern generator providing energy for solidification, and a cleaning station for removing residual material, allowing for precise control over the solidification process and material transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If supports are used to hold the object during manufacturing, then the object can be built with complex geometries, but the supports are difficult to remove without damaging the finished object
Solution Approach 1:
The patent segments the manufacturing process into distinct phases with different materials: supports are built with a removable material (first material) while the object is built with a permanent material (second material). This segmentation allows supports to be easily separated from the finished object, solving the contradiction between building complex geometries and ease of support removal.
Solution Approach 2:
The patent applies different material properties to different parts of the build: the support regions use a material with removable properties (water-soluble or meltable) while the object regions use a material with permanent, durable properties. This local differentiation of material quality enables complex geometries to be supported during manufacturing while the final object remains intact after support removal.
2Ease of manufacture
If multiple materials are used for object and supports, then supports can be easily removed, but existing processes cannot efficiently accommodate multiple materials
Solution Approach 1:
The patent employs a single pattern generator that can selectively solidify different materials (photopolymerizable support material and thermoplastic object material) using the same basic mechanism (light projection). This multi-functionality allows the system to handle multiple materials without proportionally increasing device complexity, as the pattern generator serves universal purposes for both material types.
Solution Approach 2:
The patent introduces a cleaning station as an intermediary component between material deposition and solidification. This cleaning station removes excess first material (support material) before the second material (object material) is deposited, enabling efficient multi-material processing without requiring complex integration of material handling systems. The intermediary cleaning step simplifies the overall multi-material process.
3Adaptability or versatility
If the build platform and pattern generator move relative to each other, then flexibility in manufacturing is improved, but alignment precision between the two components becomes difficult to maintain
Solution Approach 1:
The patent merges the pattern generator and build platform into a fixed relative alignment configuration, eliminating the need for complex relative motion control mechanisms. By combining these components in a fixed spatial relationship, the system maintains high alignment precision while still achieving manufacturing flexibility through other means (such as selective material deposition and solidification control).
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 accurate construction of three-dimensional objects from multiple materials, ensuring the removal of supports without damaging the finished object, improving the precision and efficiency of the manufacturing process.
Implementation Method 1
The components produced may range in size from small to large parts. The manufacture of parts may be based on various technologies including photo-polymer hardening using light or laser curing methods.
Implementation Method 2
with a cleaning station to facilitate the removal of supports by solidifying and removing unsolidified material
Data Source
AI summary
Methods and apparatuses for making three-dimensional objects from multiple solidifiable materials is shown and described. Multiple solidifiable material container assemblies are provided for holding different solidifiable materials. Relative movement between the solidifiable material container assemblies and a build platform allows the solidifiable materials to be switched as an object is built. Several exemplary cleaning stations are provided for removing residual solidifiable materials from the surface of the three-dimensional object as it is built to better ensure smooth transitions between materials on the finished object.