Peelable Sacrificial Structure for Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing methods face challenges in efficiently removing support materials from complex geometries without damaging the final product, often requiring water-jet impact, chemical dissolution, or thermal treatment.
Innovation Solution
A method and system for additive manufacturing that involves dispensing and solidifying layers of a modeling material, an elastomeric sacrificial structure, and intermediate layers with a lower elastic modulus. The sacrificial structure is then peeled off using a controlled peeling force, exposing the model layers without damaging them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If water-jet impact or chemical dissolution methods are used to remove support materials, then the support material can be effectively removed, but the final product may be damaged and hazardous chemicals or specialized equipment are required
Solution Approach 1:
The invention changes the physical parameters of the support material by using materials with different elastic moduli. The intermediate support layers have lower elastic modulus than the elastomeric sacrificial structure, enabling progressive mechanical peeling without requiring harsh chemical or thermal methods that could damage the final product
Solution Approach 2:
The support construction is segmented into multiple layers with different material properties: intermediate layers made of support material with lower elastic modulus and a sacrificial structure made of elastomeric material with higher elastic modulus. This segmentation allows selective removal of the elastomeric material through peeling while leaving the intermediate layers intact to support the final product
2Productivity
If thermal treatment is used to remove support material, then removal efficiency is improved, but energy consumption increases and risk of damaging the final product rises
Solution Approach 1:
The invention replaces thermal treatment methods with a mechanical peeling process. By applying peeling forces to the elastomeric sacrificial structure, support material is removed through mechanical deformation and separation rather than thermal decomposition, significantly reducing energy consumption while maintaining removal efficiency
Solution Approach 2:
The invention changes the removal mechanism from thermal to mechanical by utilizing the elastic modulus difference between materials. The elastomeric material's higher elasticity allows it to be peeled away mechanically without requiring the high energy input needed for thermal treatment of conventional support materials
3Strength
If conventional support constructions are used, then structural support during printing is provided, but removal of support material becomes difficult for complex geometries
Solution Approach 1:
The invention applies different material qualities to different parts of the support construction. The intermediate layers retain conventional support material properties for structural strength during printing, while the outer elastomeric sacrificial structure has modified properties (higher elasticity) that enable easy peeling and removal, especially from complex geometries
Solution Approach 2:
The support construction uses a composite structure combining conventional support material and elastomeric material with different elastic moduli. This composite approach allows the system to simultaneously achieve the structural integrity needed during printing and the ease of removal needed after printing, by having each material layer perform its specific function
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
This approach allows for the efficient removal of sacrificial structures from complex geometries without damaging the final product, offering a dry and environmentally friendly method that reduces the need for hazardous chemicals and specialized equipment.
Implementation Method 1
a sacrificial structure having a stack of sacrificial layers made of an elastomeric material... applying a peeling force to the sacrificial structure to remove the sacrificial structure
Implementation Method 2
a stack of intermediate layers made of a support material having an elastic modulus less than the elastomeric material and being between the stack of model layers and the sacrificial structure
Data Source
AI summary
A method of additive manufacturing of a three-dimensional object. The method comprises: sequentially dispensing and solidifying a plurality of layers comprising (i) a stack of model layers arranged in a configured pattern corresponding to the shape of the object and being made of a modeling material, (ii) a sacrificial structure having a stack of sacrificial layers made of an elastomeric material, and (iii) a stack of intermediate layers made of a support material having an elastic modulus less than the elastomeric material and being between the stack of model layers and the sacrificial structure; and applying a peeling force to the sacrificial structure to remove the sacrificial structure, and to expose the stack of model layers and/or the stack of intermediate layers beneath the sacrificial structure.