Water Dispersible Phase Change Support Material for 3D Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing 3D printing systems face issues with support material removal, which can leave undesirable residues and compromise the mechanical integrity of finished parts, often requiring elevated temperatures and organic carriers.
Innovation Solution
Development of a water dispersible phase change support material comprising a wax component with ethoxylated fatty alcohols and a viscosity modifying component, which solidifies upon deposition and can be easily removed by dispersing in water, eliminating the need for organic carriers and reducing part deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If heating and organic carriers are used to remove support material, then support material can be removed, but undesirable oily residue is deposited on the completed part
Solution Approach 1:
The support material composition is changed from hydrophobic to hydrophilic by incorporating water-soluble polymers and surfactants, enabling removal via water dissolution rather than organic carriers, thus eliminating oily residue
Solution Approach 2:
Water is used as an intermediary substance to remove the support material through dissolution, replacing the traditional organic carrier system and avoiding residue deposition on the part
2Loss of substance
If elevated temperatures are used to remove support material, then support material can be removed, but mechanical integrity of the finished part is compromised
Solution Approach 1:
The removal mechanism is changed from thermal melting to aqueous dissolution, allowing support material removal at ambient or low temperatures that do not compromise the mechanical integrity of the finished part
Solution Approach 2:
The thermal removal system is replaced with a chemical dissolution system using water-soluble support materials, eliminating the need for elevated temperatures and associated mechanical damage
3Ease of operation
If hydrophobic support material is used, then support material can be jetted as liquid, but organic carriers are required for removal
Solution Approach 1:
The hydrophobicity parameter of the support material is changed to hydrophilicity through incorporation of water-soluble polymers and surfactants, enabling water-based removal without organic carriers while maintaining jetting capability
Solution Approach 2:
Water replaces organic carriers as the intermediary medium for support material removal, simplifying the system by eliminating the need for specialized organic carrier handling and disposal infrastructure
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 water dispersible phase change support material effectively removes the support structure without damaging the printed part, maintaining mechanical integrity and allowing for direct disposal in wastewater treatment systems without further processing.
Implementation Method 1
phase change support materials operable for use in 3D printing systems
Implementation Method 2
solidifies by freezing once deposited on a surface during the fabrication of a three-dimensionally printed article or object
Implementation Method 3
water dispersible phase change support material described herein is fluid at jetting temperatures
Data Source
AI summary
In one aspect, support materials operable for use in 3D printing systems are described herein. In some embodiments, a support material comprises a wax component comprising at least one ethoxylated fatty alcohol and a viscosity modifying agent, wherein the support material is water dispersible. In some embodiments, the wax component comprises a mixture of at least one fatty alcohol and at least one ethoxylated fatty alcohol.