Process of support removal for fused deposition modeling
First Claim
1. A process for producing three-dimensional objects having overhanging portions freely suspended in space comprising:
- dispensing a first, solidifiable structural material in a predetermined pattern, to deposit multiple layers of said material defining a three-dimensional composite body comprised of both a three-dimensional object and a separate three-dimensional support structure underlying overhanging portions of said object requiring support during layer deposition, with the object and the support structure being separated by a space therebetween defining the underside of said overhanging portions of the object; and
dispensing a second, release material in said space between the object and the support structure, in a multiple pass deposition process coordinated with the dispensing of said first material and in contact therewith, with said second material being of a different composition than said first material such that said second material forms a weak, breakable bond with the first material in a readily separable joint in said space between the object and the support structure.
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Accused Products
Abstract
Processes and apparatus are disclosed for producing three-dimensional objects having overhanging portions freely suspended in space without any material of the object in direct, supporting engagement therewith in the final geometry of the object. A support structure is formed by depositing material which will be under the ultimately suspended portions of the object to be formed, during a process in which material is built up in layers to form the object as well as the underlying support structure. A readily removable support structure is formed along an interface with the underside of the suspended portion of the object structure. A weak, removable or breakable joint is formed along that interface by the use of an interface material which forms a weak or dissolvable bond with the material of the object. The release material may be deposited as a separation layer, or as a thin coating.
544 Citations
14 Claims
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1. A process for producing three-dimensional objects having overhanging portions freely suspended in space comprising:
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dispensing a first, solidifiable structural material in a predetermined pattern, to deposit multiple layers of said material defining a three-dimensional composite body comprised of both a three-dimensional object and a separate three-dimensional support structure underlying overhanging portions of said object requiring support during layer deposition, with the object and the support structure being separated by a space therebetween defining the underside of said overhanging portions of the object; and dispensing a second, release material in said space between the object and the support structure, in a multiple pass deposition process coordinated with the dispensing of said first material and in contact therewith, with said second material being of a different composition than said first material such that said second material forms a weak, breakable bond with the first material in a readily separable joint in said space between the object and the support structure. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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Specification