3D Printed Support Structure Packaging for Additive Manufacturing

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Solution Overview

Problem

Three-dimensional (3D) models built using digital manufacturing systems are often damaged during packaging, storage, and shipping due to lack of adequate protection, especially for models with fine features, necessitating a solution to enhance their safety and efficiency during transit.

Innovation Solution

A method where a support structure is built using layer-based additive techniques to encase and protect 3D models, functioning as both a shipping package and providing vertical support during construction, utilizing materials like thermoplastic and water-soluble support materials that can be easily removed post-shipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional separate packaging is used for 3D models, then packaging simplicity is maintained, but protection against damage during shipping is insufficient

Engineering Contradiction:

Improveprotection against damageVSAvoidpackaging structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The support structure required for building the 3D model is merged with the shipping package function. The same support material that provides structural support during additive manufacturing is retained to form a protective enclosure around the finished model, eliminating the need for separate packaging while providing enhanced protection during shipping and storage.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The support structure is designed to serve multiple functions: it provides vertical support during the build process, acts as a protective shipping package, and can be easily removed after delivery. This multi-functionality resolves the contradiction by making the support structure both necessary for manufacturing and beneficial for protection, without requiring additional packaging components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If adequate protective packaging is provided for 3D models, then damage protection is improved, but shipping costs increase

Engineering Contradiction:

Improvedamage protectionVSAvoidpackaging material

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If support structure is used during building, then manufacturing capability for complex geometries is improved, but removal difficulty increases

Engineering Contradiction:

Improvecomplex geometry capabilityVSAvoidsupport structure removal

Core Design Contradiction:

Ease of manufactureVSEase of repair

Solution Approach 1:

The support material's physical or chemical parameters are changed after the build process to facilitate easy removal. This could involve using water-soluble materials that dissolve when exposed to moisture, or materials that soften at specific temperatures, transforming the support structure from a firmly adhered state during building to an easily separable state for removal, thus resolving the contradiction between manufacturing capability and removal difficulty.

Inventive Principle:

Principle #35Parameter changes

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 support structure effectively protects 3D models from damage during storage and transit, reduces shipping costs, and ensures the models arrive intact, while also minimizing material usage and build time for the support structure.

Implementation Method 1

digital manufacturing systems are used to build 3D models from digital representations of the 3D models using one or more layer-based additive techniques

Methodology Applied

Scientific EffectLayer-based additive manufacturing: 3D Printing

Implementation Method 2

The extruded modeling material fuses to previously deposited modeling material, and solidifies upon a drop in temperature

Methodology Applied

Scientific EffectFusion and solidification: Melting

Data Source

PatentUS8155775B2Support structure packaging

Publication Date: 2012.04.10 STRATASYS INC

AI summary

A method comprising building at least one three-dimensional model and a support structure using a layer-based additive technique, where the at least one three-dimensional model is at least partially encased in the support structure, and where the support structure functions as a shipping package for the at least one three-dimensional model.