Peelable Sacrificial Structure for Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing methods require complex and costly processes for removing sacrificial structures, which are not suitable for home or office use due to the need for dedicated equipment and potential mess, and often involve hazardous materials or long dissolution times.
Innovation Solution
A method and system for additive manufacturing that uses a flexible material as a sacrificial structure, which can be easily peeled away from the object in a dry environment, along with a soft material for intermediate support, allowing for quick and tidy removal without solvents or dedicated equipment, and a compact inkjet printing system that can produce full-colored objects with a peelable sacrificial structure.
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 sacrificial structure can be removed, but the process becomes complex, costly, and requires dedicated equipment that is not suitable for home or office use
Solution Approach 1:
The patent replaces complex mechanical removal systems (water-jet impact devices, chemical dissolution equipment) with a simple manual peeling action. The flexible material is designed to be peelable by hand, eliminating the need for dedicated removal equipment and making the process suitable for home or office use.
Solution Approach 2:
The flexible sacrificial structure is designed as a disposable component that is easily removed and discarded after serving its support function. This aligns with the principle of using cheap, short-living objects where the removal process is simplified by accepting the sacrificial material as single-use.
2Ease of manufacture
If chemical dissolution methods are used to remove support materials, then the sacrificial structure can be removed, but hazardous materials and potential mess are involved
Solution Approach 1:
The patent substitutes chemical dissolution methods with a mechanical peeling action. Instead of using solvents or chemicals that create hazardous conditions and mess, the flexible material is simply peeled off the printed object by hand, eliminating exposure to harmful substances and keeping the work environment clean.
3Ease of manufacture
If water soluble support material is used, then the sacrificial structure can be removed by immersion, but the process requires long dissolution times
Solution Approach 1:
The patent replaces the slow chemical dissolution process with a fast mechanical peeling action. The flexible sacrificial structure is designed to be manually peeled off in seconds, eliminating the hours-long immersion time required for water-soluble support materials to dissolve completely.
Solution Approach 2:
The patent changes the removal mechanism from a time-dependent chemical dissolution process to an instantaneous mechanical peeling process. By altering the removal method from chemical to mechanical, the time parameter is dramatically reduced from hours to seconds.
4Ease of manufacture
If a single flexible material is used for both the sacrificial structure and intermediate support, then material selection is simplified, but the intermediate structure may not provide adequate support during peeling
Solution Approach 1:
The patent applies different material properties to different regions of the support structure. The sacrificial structure uses a peelable flexible material, while the intermediate support structure uses a stiffer material with higher elastic modulus to provide adequate mechanical support during the peeling process. This local differentiation of material properties ensures both peelability and structural integrity.
Solution Approach 2:
The patent employs a composite support system combining two different materials: a flexible peelable material for the sacrificial structure and a stiffer material for the intermediate support. This composite approach allows each material to perform its specific function optimally - the flexible material enables easy removal while the stiffer material provides necessary structural support.
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 efficient and environmentally friendly removal of sacrificial structures, reducing waste and operational complexity, while maintaining the mechanical properties of the printed object, and is suitable for home or office use with a compact and user-friendly printing system.
Implementation Method 1
a flexible material and forming a sacrificial structure... having an elastic modulus less than the flexible material
Implementation Method 2
3D printing processes, for example, 3D inkjet printing, are being performed by a layer by layer inkjet deposition of building materials
Implementation Method 3
sequentially dispensing and solidifying a plurality of layers
Data Source
AI summary
A method of additive manufacturing of a three-dimensional object includes sequentially dispensing and solidifying a plurality of layers. The plurality of layers may be formed with a plurality of different colored model materials, a flexible material arranged in a configured pattern to form a sacrificial structure at least partially encompassing the object, and a soft material. The soft material is arranged in a configured pattern to provide separation between the model material and the sacrificial structure. The plurality of different colored model materials is arranged in a configured pattern corresponding to the shape and color definition of the object.