Designs & Processes for Facilitating Easy Removal of Support Structures in 3D Printing

A thermally decomposable build plate for additive manufacturing that enables easy release of 3D printed metal parts without damaging the parts or build plate. The build plate is an open frame with a recessed section filled with a lower-temperature melting metal or alloy insert. After printing, the insert can be melted and drained to release the 3D printed part without mechanical cutting. The lower melting insert protects the build plate, allows separation without damage, and reuses the plate.

3D printing method that enables 3D printing complex shaped objects with removable supports. The method involves 3D printing the object using a shaping material like metal or ceramic powder and simultaneously 3D printing supports around the object using a removable resin material. After printing, the supports are removed by heating, vaporizing, or dissolving the resin. This enables the creation of complex 3D shapes with internal voids and overhangs that would otherwise require difficult support removal.

Automatically optimize the support removal process for 3D printed parts by using historical and real-time data from the support removal machine to decide which agitation methods to activate and adjust.

Optimizing the operation of a machine that removes support material from 3D-printed parts to maximize efficiency and avoid damage involves using an operation model that analyzes real-time data from the removal process to identify the best parameters for each consecutive interval of the process.

A method to reduce the number of post-processing steps required after 3D printing is using a multi-layer 3D printing technique. The method involves printing multiple layers simultaneously, rather than one layer at a time, using a 3D printer with multiple print heads. This reduces the need for support structures by allowing overhanging features to be supported by adjacent layers. The simultaneous printing of layers also allows different materials to be printed together. The multi-layer printing technique simplifies post-processing by reducing the need for support removal, sorting, cleaning, and packaging.

Optimized 3D printing to minimize marks from support structures on printed objects. The method involves overcuring regions of the object near the support structures that will remain as marks when supports are removed. By overcuring those regions, the surface is made to project past the marks once the supports are removed, which flattens it to the desired profile. This eliminates the need for post-processing, like sanding, to remove support marks and achieve smooth surfaces.

A method to reduce or eliminate visible support marks on 3D printed objects. The method involves adding overcure regions to the object during printing - regions where extra material is deposited. When the support structures are removed, any remaining support marks are recessed below the overcured regions, leaving a smooth surface.

Creating optimized support structures for 3D printed objects that balance providing proper support during fabrication with easy removal after printing. The structure uses tearaway supports that are interconnected but have minor contact points with the object, allowing them to be easily torn off. The supports also have untrussed upper sections and adjustable join geometries to reduce tearing forces.

A sacrificial support material for 3D printing that can be easily removed from printed objects. It is made from an epoxy resin containing isosorbide diglycidyl ether and a curing agent. The sacrificial support material can be printed alongside the main object and then dissolved away after printing using a solvent that doesn't affect the main object. The isosorbide-based sacrificial support enables complex hollow structures to be 3D printed, that would be difficult or impossible with conventional supports.

A 3D printing method that allows for easy release of support structures without leaving residue or damaging the printed object. It involves applying a low surface energy release material layer onto the object surface before printing. The release layer has a surface energy of 25 mN/m or lower. This prevents adhesion between the printed material and the support material. After printing, the release material can be applied using a separate print head or spraying/coating. The low surface energy release layer allows the supports to be easily detached after printing without residue or damage.

Using a rotating fluid jet to remove support material from 3D printed objects in a way that is more efficient and less damaging than traditional methods. The method involves inserting the printed objects into a container, then using a rotating fluid jet to vigorously agitate the objects. The jet collisions and turbulence help loosen and remove the support material from the printed objects.

Post-processing technique to remove support material from a 3D printed object without damaging the object. The technique involves heating the printed object to melt the support material, draining off the melted support material, and then immersing the object in a liquid to remove any remaining support material.