Weak-Gel Support Material for Complex 3D Printing Removal

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Solution Overview

Problem

Current additive manufacturing processes face difficulties in efficiently and cleanly removing support materials from intricate geometries, such as hollow structures, enclosed volumes, and entangled tubular structures, often causing damage and requiring labor-intensive and time-consuming methods.

Innovation Solution

A curable formulation is developed that forms a weak gel upon curing, allowing for easy removal by applying positive pressure, which is suitable for 3D inkjet printing and other additive manufacturing techniques, enabling the formation of complex geometries with minimal damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If support materials are used to enable complex geometries in additive manufacturing, then the ability to form intricate structures is improved, but the difficulty and time required for support removal increases

Engineering Contradiction:

Improveability to form complex geometriesVSAvoidsupport removal time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The support material's physical and chemical parameters are specifically designed to enable easy removal. The formulation includes water-soluble polymers, salts, and surfactants that allow the support material to be dissolved or dispersed in water, transforming the removal process from mechanical to chemical, thereby reducing removal time and effort while maintaining the ability to support complex geometries during printing

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If mechanical methods are used for support material removal, then removal capability is improved, but the risk of damage to the printed object increases

Engineering Contradiction:

Improvesupport removal capabilityVSAvoiddamage to printed object

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent replaces mechanical support removal methods with chemical dissolution methods. The support material is formulated to dissolve in water or aqueous solutions, eliminating the need for mechanical impact, water-jet, or manual removal that could damage intricate printed structures. This substitution of mechanical action with chemical action resolves the contradiction between removal capability and object integrity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If chemical dissolution methods are used for support removal, then ease of removal is improved, but the process becomes labor-intensive and requires special equipment

Engineering Contradiction:

Improvesupport removal easeVSAvoidspecial equipment requirement

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The support material is designed as a disposable, sacrificial component that dissolves completely in water without requiring specialized removal equipment. The formulation uses common water-soluble materials that can be removed by simple immersion in water or aqueous solutions, eliminating the need for expensive specialized equipment or labor-intensive processes while maintaining ease of operation

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Strength

If support material has high mechanical strength to hold model material, then structural support capability is improved, but the difficulty of support removal increases

Engineering Contradiction:

Improvesupport material mechanical strengthVSAvoidsupport removal ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The support material is formulated with local quality differentiation: it possesses sufficient mechanical strength and structural integrity during the printing process to support complex geometries, but contains water-soluble components that enable easy dissolution during removal. This dual characteristic is achieved by combining structural polymers with water-soluble additives, allowing the same material to fulfill both contradictory requirements at different stages

Inventive Principle:

Principle #3Local quality

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 formulation allows for efficient and clean removal of support materials from intricate geometries, reducing processing time and preserving the integrity of the printed object.

Implementation Method 1

a curable formulation which provides, when hardened, a material that features properties of a weak gel

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS12606703B2Additive manufacturing using materials that form a weak gel

Publication Date: 2026.04.21 STRATASYS LTD

AI summary

A formulation usable in additive manufacturing of a three-dimensional object is provided. The formulation comprises one or more monofunctional curable material(s); one or more hydrophilic multifunctional curable material(s); and one or more water-miscible non-curable material(s), such that a total amount of the curable materials is 20% or less, by weight, and a weight ratio of a total weight of the monofunctional curable material(s) and a total weight of the hydrophilic multifunctional curable material(s) ranges from 1:1 to 10:1. The formulation features, when hardened, properties of a weak and flowable gel. Additive manufacturing processes utilizing the formulation as a support material formulation are also provided.