Solvent-Based Support Removal for Additive Manufacturing
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Solution Overview
Problem
Current methods for removing support materials in additive manufacturing are inefficient, often requiring harsh chemicals, long processing times, and manual removal, which can damage the building material and pose safety concerns, especially for complex shapes.
Innovation Solution
A method using a thermoplastic build material and a polymeric support material that can be selectively removed through immersion in a solvent, either by softening or dissolving, to facilitate easy separation without damaging the build material, reducing processing time and eliminating the need for harsh chemicals and manual tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If harsh chemicals are used to remove soluble support material, then the support material can be removed, but the building material may be damaged or degraded and the process requires long processing times
Solution Approach 1:
The patent changes the chemical parameters by selecting a solvent specifically matched to the polymeric support material composition. This allows the support material to be removed through dissolution without requiring harsh chemicals that would damage the thermoplastic build material, resolving the contradiction between complete support removal and building material preservation
Solution Approach 2:
The patent introduces a specific solvent as an intermediary substance that selectively interacts with the polymeric support material. This intermediary enables the removal process to proceed without direct contact between harsh chemicals and the building material, thus protecting the building material while achieving complete support removal
2Object-affected harmful factors
If manual removal of non-soluble support material is used, then no harsh chemicals are needed, but the process is difficult for complex objects and may present safety concerns
Solution Approach 1:
The patent replaces the mechanical removal system (manual tools) with a chemical dissolution system using a selected solvent. This substitution eliminates the difficulties of manual removal for complex geometries while avoiding safety concerns associated with manual tools, and does not require harsh chemicals
3Object-affected harmful factors
If manual tools are used for support material removal, then no harsh chemicals are required, but the tools may not be able to completely remove support material from complex shapes without damage to parts
Solution Approach 1:
The patent replaces mechanical removal tools with a solvent-based chemical dissolution process. This allows the solvent to penetrate and dissolve support material from complex internal geometries that mechanical tools cannot access, achieving complete removal without damaging the part
Solution Approach 2:
The solvent acts as an intermediary that can access and dissolve support material in locations inaccessible to manual tools, enabling complete removal from complex shapes without requiring harsh chemicals or mechanical force that could damage the part
4Ease of manufacture
If soluble support material is used, then support material can be removed chemically, but the process requires harsh chemicals and long processing times
Solution Approach 1:
The patent changes the chemical composition parameters of both the support material and the solvent to create a matched pair. This optimization allows the support material to dissolve rapidly in the selected solvent without requiring harsh chemicals or extended processing times, resolving the contradiction between ease of removal and processing time
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 complete and safe removal of support materials from complex shapes without damaging the build material, reducing processing time and eliminating the use of harsh chemicals, ensuring efficient and precise support material removal.
Implementation Method 1
selectively dissolving the polymeric support material with the solvent
Implementation Method 2
selectively softening the polymeric support material with the solvent
Data Source
AI summary
An article and a method of forming an article are provided. The article includes a thermoplastic build material and a polymeric support material. The polymeric support material is selectively removable from the thermoplastic build material through immersion in a solvent. The method of forming an article includes forming a part through additive manufacturing with a thermoplastic build material and a polymeric support material, immersing the part in a solvent, selectively softening the polymeric support material with the solvent, removing the part from the solvent, and separating the polymeric support material from the thermoplastic build material. Another method of forming an article includes forming a part through additive manufacturing with a thermoplastic build material and a polymeric support material, immersing the part in a solvent, selectively dissolving the polymeric support material with the solvent, and removing the thermoplastic build material from the solvent.