Polymeric Composition for Temporary Support in 3D Printing
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Solution Overview
Problem
Current temporary support materials in FDM/FFF 3D printing face challenges such as strong adhesion to the model, labor-intensive removal, moisture absorption leading to printing issues, and the use of hazardous solvents, which complicates the process and increases costs.
Innovation Solution
A polymeric composition with a continuous phase of a second immiscible component and a discontinuous phase of the modeling material, offering a Shore A hardness of at least 80, allowing for easy mechanical removal without damaging the part and eliminating the need for hazardous solvents, while maintaining a long shelf life and printing quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional temporary support materials are used in FDM/FFF 3D printing, then support structures can be provided during printing, but removal of the support structures becomes labor-intensive and time-consuming
Solution Approach 1:
The patent changes the physical-chemical parameters of the support material by creating a polymer blend with specific composition ratios (first polymer 10-40 wt%, second polymer 60-90 wt%). This parameter change results in a material that maintains structural support during printing but allows for easy, low-labor removal afterward, resolving the contradiction between providing support and enabling easy removal.
Solution Approach 2:
The invention uses a composite polymeric material consisting of two immiscible polymers with different properties. The first polymer provides adhesion and structural integrity during printing, while the second polymer enables easy removal. This composite approach allows the support structure to fulfill its support function while being easily removable, addressing the technical contradiction.
2Ease of manufacture
If water-soluble temporary support materials are used, then support structures can be removed by dissolution, but the materials absorb moisture from the atmosphere leading to printing issues
Solution Approach 1:
The patent modifies the moisture absorption parameter of the support material by selecting polymers with appropriate hydrophobicity. The blend composition and polymer selection ensure the material remains sufficiently hydrophobic to resist atmospheric moisture absorption during storage and printing, while still being removable afterward. This parameter optimization resolves the contradiction between easy removal and printing reliability.
3Ease of manufacture
If solvent-soluble temporary support materials are used, then support structures can be removed by dissolution, but hazardous solvents are required increasing cost and complexity
Solution Approach 1:
The patent employs a disposable support material that can be removed through simple mechanical means or mild solvent exposure, eliminating the need for complex hazardous solvent handling systems. The support material is designed to be inexpensive and easily disposed of, resolving the contradiction between easy removal and system complexity.
Solution Approach 2:
The invention introduces a mild solvent or mechanical action as an intermediary method to remove the support structure, replacing the need for hazardous solvents. This intermediary approach simplifies the removal process and eliminates the complexity of handling dangerous chemicals, while still achieving effective support structure removal.
4Strength
If strong adhesion is provided between support material and model material, then support structures remain stable during printing, but removal becomes difficult and may damage the part
Solution Approach 1:
The patent optimizes the adhesion parameter by controlling the composition ratio and selecting appropriate polymer pairs. The blend is designed to provide sufficient adhesion for stable support during printing, but the adhesion strength is tuned to allow for easy removal without damaging the part. This parameter optimization resolves the contradiction between stability and ease of removal.
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 polymeric composition enables efficient and labor-saving removal of support structures without compromising the quality of the printed parts, reducing printing speed, cost, or printer complexity, and extends the shelf life by minimizing water absorption and avoiding hazardous solvents.
Implementation Method 1
a polymeric composition with a continuous phase of a second immiscible component and a discontinuous phase of the modeling material
Data Source
AI summary
The polymeric composition of this invention can be used as a temporary support material in the additive manufacturing of three dimensional articles without compromising ultimate product quality, reducing printing speed, requiring printers of increased complexity, or increasing cost or the incidence of printer jamming. This invention more specifically discloses a polymeric composition which is useful as a temporary support material for utilization in three-dimensional printing, this polymeric composition comprising of a first polymeric component which is suitable for use as a modeling material and a second polymeric component which is immiscible with the first polymeric component, wherein the polymeric composition has a continuous phase which is comprised of the second polymeric component, and wherein the polymeric composition has a Shore A hardness of at least 80.