3D Printed Shell Molds with Sacrificial Supports

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Solution Overview

Problem

3-D printing technologies face challenges in mass production due to the time-consuming and costly nature of customizing each part individually, and the difficulty in printing structures with overhangs and complex geometries without support structures.

Innovation Solution

The use of sacrificial layers and flexible platforms with nozzles of varying sizes to optimize support structures, combined with post-printing processes like solvent vapor smoothing and combinatorial casting to enhance throughput and material efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If support structures are used to print complex geometries with overhangs, then manufacturing capability is improved, but material usage and post-processing complexity increase

Engineering Contradiction:

Improvemanufacturing capabilityVSAvoidmaterial usage

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent extracts and removes support structures from the final product by using dissolvable materials that can be selectively eliminated through chemical dissolution, leaving only the desired complex geometry without unnecessary material

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs porous or lattice-based support structures that reduce material consumption while maintaining structural functionality during printing, allowing for easier removal and reduced post-processing requirements

Inventive Principle:

Principle #31Porous materials

2Manufacturing precision

If high-resolution nozzles are used to print detailed features, then manufacturing precision is improved, but printing speed decreases

Engineering Contradiction:

Improvehigh-resolution featuresVSAvoidprinting speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent segments the printing process into multiple passes with different nozzle sizes, using fine nozzles for high-resolution features and coarse nozzles for bulk material deposition, thereby achieving both precision and speed

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies partial action by using high-resolution printing only where necessary for specific features, while using lower resolution for other portions of the object, optimizing the balance between precision and productivity

Inventive Principle:

Principle #16Partial or excessive action

3Ease of operation

If sacrificial materials are used in support structures, then ease of removal is improved, but material cost increases

Engineering Contradiction:

Improveease of removalVSAvoidmaterial cost

Core Design Contradiction:

Ease of operationVSQuantity of substance

Solution Approach 1:

The patent changes the chemical parameters of the support material by using dissolvable substances that can be selectively removed through chemical reactions, making removal easier while controlling material selection to minimize cost

Inventive Principle:

Principle #35Parameter changes

4Productivity

If mass production of customized parts is attempted, then productivity should improve, but time and cost increase due to individual customization

Engineering Contradiction:

Improvemass production capabilityVSAvoidproduction time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent achieves universality by using standardized printing platforms, nozzle systems, and material formulations that can accommodate various customized designs, enabling mass production of personalized parts through a single flexible system

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 enables faster and more cost-effective production of complex structures with reduced material usage, improved thermal insulation, and enhanced surface finish, while allowing for the creation of high-resolution features and complex geometries.

Implementation Method 1

The casting process can use a dissolvable coating material, which can be dissolved in a chemical liquid after the object is cast

Methodology Applied

Scientific EffectDissolution: Solvation

Implementation Method 2

The surface of the printed object can be smoothened, for example, by solvent vapor (such as acetone for plastic)

Methodology Applied

Scientific EffectVapor deposition: Deposition (physical)

Implementation Method 3

Objects having porous walls can be printed to obtain high thermal insulating property

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS10751951B13-D printed materials, structures and processes

Publication Date: 2020.08.25 NGUYEN TAI DUNG

AI summary

Molds including 3D printed components can be used to cast objects. A model of the object can be separated into multiple components, with each component not having non-printable overhang structures, thus allowing the components to be directly printed without support structures. Shell models and shell molds, e.g., molds with hollow interior, can be used for cost effectiveness. The surface of the printed object can be smoothened, for example, by solvent vapor (such as acetone for plastic), by sanding, or by a smooth coating. The object can be combinatorially cast.