SUPPORT STRUCTURE PACKAGING

• US 20100086721A1
• Filed: 10/01/2009
• Published: 04/08/2010
• Est. Priority Date: 10/02/2008
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Batchelder, J. Samuel
• Granted Patent: US 8,155,775 B2
• Time in Patent Office: Days
• US Class Current: 428/43
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29L 2031/712 Containers; Packaging elements or accessories, Packages closures therefor B29L2031/56; ink or toner cartridges B29L2031/7678; squeeze tubes B29L2023/20; suitcases B29L2031/7418
• CPC Class Codes: B29L 2031/7164 Blister packages
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/00 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B65D 81/113 of a shape specially adapted to accommodate contents B65D81/053 takes precedence
• CPC Class Codes: Y10T 428/15 Sheet, web, or layer weakened to permit separation through thickness

Abstract

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.

Claims

1. A three-dimensional object comprising:

at least one three-dimensional model built using a layer-based additive technique; and

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

2. The three-dimensional object of claim 1, wherein the support structure extends around the at least one three-dimensional model in each coordinate direction by at least a predetermined offset distance.

3. The three-dimensional object of claim 1, wherein the at least one three-dimensional model is fully encased in the support structure.

4. The three-dimensional object of claim 1, wherein the support structure comprises a shipping label built using the layer-based additive technique.

5. The three-dimensional object of claim 1, wherein the layer-based additive technique is performed with a deposition-based digital manufacturing system selected from the group consisting of an extrusion-based system, an ink jetting system, and combinations thereof.

6. The three-dimensional object of claim 1, wherein the support structure is built from a support material selected from the group consisting of a water-soluble support material, a break-away support material, and combinations thereof.

7. The three-dimensional object of claim 1, wherein the support structure is built with at least one build style feature selected from the group consisting of a skin portion, a reinforcing rib, a reinforcing strut, fluid channels, handle indentations, and combinations thereof.

8. A method of building and using a support structure, the method comprising:

building at least one three-dimensional model using a layer-based additive technique;

building the support structure using the layer-based additive technique such that the built support structure at least partially encases the at least one three-dimensional model; and

shipping the at least one built three-dimensional model while at least partially encased in the built support structure.

9. The method of claim 8, wherein the support structure is built such that the built support structure fully encases the at least one built three-dimensional model.

10. The method of claim 8, and further comprising generating a digital representation of the support structure based at least in part on a digital representation of the at least one three-dimensional model.

11. The method of claim 10, wherein generating the digital representation of the support structure comprises:

generating a first digital representation of the support structure based on at least one overhanging region of the digital representation of the at least one three-dimensional model; and

generating a second digital representation of the support structure based at least in part on dimensions of the digital representation of the at least one three-dimensional model.

12. The method of claim 11, wherein the second digital representation of the support structure is generated based at least in part on a predetermined offset distance from at least one exterior surface of the digital representation of the at least one three-dimensional model.

13. The method of claim 8, and further comprising building a shipping label on an exterior surface of the support structure using the layer-based additive technique.

14. The method of claim 8, and further comprising removing the support structure from the at least one three-dimensional model after the shipping.

15. A method for providing a three-dimensional model to a customer based on a digital representation of the three-dimensional model, the method comprising:

generating a first digital representation of a support structure based on at least one overhanging region of the digital representation of the three-dimensional model;

generating a second digital representation of the support structure based on dimensions of the digital representation of the three-dimensional model;

generating build data based at least in part on the digital representation of the three-dimensional model, the first digital representation of the support structure, and the second digital representation of the support structure;

building the three-dimensional model and the support structure with a digital manufacturing system based on the build data such that the built support structure at least partially encases the three-dimensional model; and

shipping the built three-dimensional model while at least partially encased in the built support structure.

16. The method of claim 15, wherein the support structure is built such that the built support structure fully encases the built three-dimensional model.

17. The method of claim 15, and further comprising receiving the digital representation of the three-dimensional model.

18. The method of claim 15, and further comprising:

receiving shipping information from the customer;

generating a digital representation of a shipping label, wherein the generated build data is further based on the digital representation of the shipping label; and

building the shipping label on the support structure with the digital manufacturing system based on the build data.

19. The method of claim 15, wherein the digital manufacturing system comprises a deposition-based digital manufacturing system selected from the group consisting on an extrusion-based system, an ink jetting system, and combinations thereof.

20. The method of claim 15, wherein the support structure is built from a support material selected from the group consisting of a water-soluble support material, a break-away support material, and combinations thereof.