3D Printed Support Structure with Ceramic Skeleton and Removable Fill
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Solution Overview
Problem
Current FDM metal 3D printing methods face difficulties in efficiently and safely removing support structures from complex or thin-walled workpieces due to high bonding forces, often resulting in damage to the workpiece during physical removal processes.
Innovation Solution
A method involving configuring a specific printing scheme and model for the workpiece support using a double nozzle 3D printer, which prints a skeleton with gaps to reduce bonding forces, allowing for easy disassembly, and using a ceramic wire and linear material to fill the skeleton, facilitating the use of physical methods for support removal without damaging the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a support structure is printed using the same material as the whole structure with a ceramic material layer added for isolation, then the bonding force between the ceramic material layer and both the workpiece and support structure increases, but it becomes extremely difficult to remove the support without damaging the workpiece
Solution Approach 1:
The support structure is divided into two distinct parts: a skeleton made of ceramic material and a filling material that is different from the workpiece material. This segmentation allows the support to be selectively removed after printing, as the filling material can be differentiated and removed without affecting the workpiece, thus resolving the contradiction between strong bonding during printing and easy removal after printing.
Solution Approach 2:
Different materials are used for different parts of the support structure. The skeleton uses ceramic material for high bonding strength, while the filling uses a different material that facilitates removal. This local differentiation of material properties allows the support to provide necessary strength during printing while enabling easy removal afterward, resolving the bonding strength versus removal difficulty contradiction.
2Ease of operation
If physical methods are used to remove the support structure, then the bonding force must be overcome, but this causes damage to complex workpieces and thin-walled structures
Solution Approach 1:
The invention changes the material parameters of the support structure by using different filling materials that can be selectively removed. This allows support removal through chemical or selective dissolution processes rather than forceful physical methods, thereby maintaining workpiece integrity while achieving easy support removal, especially for complex and thin-walled structures.
3Device complexity
If the same material is used for the support structure and workpiece, then the printing process is simpler, but the support removal requires extremely high human effort and cost
Solution Approach 1:
The support structure is segmented into a ceramic skeleton and a removable filling portion made of different material. This segmentation enables automated or semi-automated removal processes that are much faster and less labor-intensive than manual physical removal, significantly reducing the time and cost associated with support removal while maintaining relatively simple printing procedures.
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 simplifies and improves the efficiency of support removal for complex and thin-walled workpieces by reducing bonding forces, ensuring the workpiece remains undamaged during disassembly and reducing the need for excessive human effort and cost.
Implementation Method 1
After being heated to a molten state by a printing nozzle, the printing wire is deposited layer by layer to form a green part.
Implementation Method 2
Then, part of the polymer material is removed by an acid-catalyzed decomposition reaction to obtain a brown part.
Implementation Method 3
Finally, the brown part is sintered under high temperature to obtain a metal part.
Data Source
AI summary
3D printing methods for workpiece supports, support structures, and workpieces having supports are disclosed. In an embodiment, a printing method of a workpiece support includes the following steps. (1) Configuring a first printing scheme by a printing software installed in a printing apparatus and configuring a workpiece support model according to the first printing scheme. (2) Printing a workpiece support skeleton according to the first printing scheme and the workpiece support model by the printing apparatus and obtaining the workpiece support by filling the workpiece support skeleton. Optionally, step (2) includes controlling a second nozzle to eject a ceramic wire according to the first printing scheme and the support model and controlling a first nozzle to eject a linear material according to the support model to fill the workpiece support skeleton.