WO2015070165A1

WO2015070165A1 - Support structure removal for 3d printed parts

Info

Publication number: WO2015070165A1
Application number: PCT/US2014/064855
Authority: WO
Inventors: Brent MOSHER; Claudia Mosher
Original assignee: Mosher Brent; Claudia Mosher
Priority date: 2013-11-11
Filing date: 2014-11-10
Publication date: 2015-05-14

Abstract

Embodiments of the invention include a method for removing the support structure from a three dimensional printed object. In an embodiment, the invention includes removing the support structure using an electrolytic solution. Other embodiments are also included herein.

Description

SUPPORT STRUCTURE REMOVAL FOR 3D PRINTED PARTS

This application is being filed as a PCT International Patent application on November 10, 2014 in the name of Brent Mosher, a U.S. Citizen, and Claudia Mosher, a U.S. Citizen, applicants and inventors for the designation of all countries, and claims priority to U.S. Provisional Patent Application No. 61/902,569, filed November 11, 2013 the contents of which is herein incorporated by reference in its entirety.

Field of the Invention

The present invention relates to 3D printing. More specifically, the present invention relates to the removal of support material in 3D printing.

Background of the Invention

Three-dimensional ("3D") printers are able to create a solid 3D object from a digital model, such as a computer aided design model. 3D printers often use a polymer based material to create the object. The polymer is normally disposed in layers, such that the object is built up. The polymer is at least in a partially liquid form when it is disposed in it desired location. The polymer can take some time to dry and become rigid. In some cases a support structure, such as scaffolding, is printed along with the object to provide support for at least a portion of the object while it dries and becomes rigid.

The support structure can be removed once the object has sufficiently dried. The support structure can be removed, such as by cutting or dissolving the support structure. In some cases the object can be submerged into a substance that dissolves the support structure. In some systems the support structure can be dissolved using sodium hydroxide or sodium percarbonate. Current systems can require the sodium hydroxide or sodium percarbonate to be heated, such as 70°C to 80°C, and can require long soak times, such as 8+ hours.

3D printers are becoming popular for rapid prototyping products where users desire prototypes quickly. Additionally, sodium hydroxide and sodium percarbonate require a user to use personal protective equipment. Accordingly, there is a need for solution to dissolve support structures that can dissolve the support structure quickly and the solution can be safe for the user. Summary of the Invention

In an embodiment, a method of creating an object including printing a 3- dimensional object with a printer, wherein the object is printed along with a removable support structure, wherein the removable support structure is configure to support at least a portion of the object while the object dries. Additionally the method can include removing the removable support structure by applying an electrolytic solution to the removable support structure.

In an embodiment, the electrolytic solution comprises catholyte water.

In an embodiment, applying an electrolytic solution can include submerging the object and removable support structure into the electrolytic solution.

In an embodiment, the ORP of the electrolytic solution is at least -lOOmV and not more than -1200mV.

In an embodiment, the pH of the electrolytic solution is at least 9 and not more than 14.

In an embodiment, the electrolytic solution has a rating of 1 or less on the Hazardous Materials Identification System ("HMIS") chart.

In an embodiment, electrolytic solution is less than 80 °C.

In an embodiment, the support structure comprises an acrylic copolymer, such as a thermoplastic acrylic copolymer containing triphenyl phosphate. In some implementations the support structure comprises a terpolymer of methacrylic acid, styrene, and butylacrylate. In the alternative, a wax composition or blend can be used.

In an embodiment, the electrolytic solution comprises a concentrate and water.

In an embodiment, the electrolytic solution is 90% or less water.

This summary is an overview of some of the teachings of the present application and is not intended to be an exclusive or exhaustive treatment of the present subject matter. Further details are found in the detailed description and appended claims. Other aspects will be apparent to persons skilled in the art upon reading and understanding the following detailed description and viewing the drawings that form a part thereof, each of which is not to be taken in a limiting sense. The scope of the present invention is defined by the appended claims and their legal equivalents. Brief Description of the Figures

The invention may be more completely understood in connection with the following drawings, in which:

FIG. 1 is a perspective view of a 3D printed part with a support structure, according to an embodiment.

FIG. 2 is a perspective view of a 3D printed part after the support structure has been removed, according to an embodiment.

FIG. 3 is a cross-section view of a 3D printed part with a support structure, according to an embodiment.

FIG. 4 is a cross-section view of a 3D printed part after the support structure has been removed, according to an embodiment.

FIG. 5 is a perspective view of a system to remove a support structure from a 3D printed part, according to an embodiment.

FIG. 6 is a flow chart of a method for removing a support structure from a 3D printer part, according to an embodiment.

FIG. 7 is a perspective view of a system to remove a support structure from a 3D printed part, according to an embodiment.

FIG. 8 is a flow chart of a method for removing a support structure from a 3D printer part, according to an embodiment.

FIG. 9 is a perspective view of a system to remove a support structure from a 3D printed part, according to an embodiment.

FIG. 10 is a flow chart of a method for removing a support structure from a 3D printer part, according to an embodiment.

FIG. 11 is a perspective view of a system to remove a support structure from a

3D printed part, according to an embodiment.

FIG. 12 is a flow chart of a method for removing a support structure from a 3D printer part, according to an embodiment.

FIG. 13 is a view of an electrolytic solution generator, according to an embodiment.

FIG. 14 is a view of a probe of an electrolytic solution generator, according to an embodiment.

While the invention is susceptible to various modifications and alternative forms, specifics thereof have been shown by way of example and drawings, and will be described in detail. It should be understood, however, that the invention is not limited to the particular embodiments described. On the contrary, the intention is to cover modifications, equivalents, and alternatives falling within the spirit and scope of the invention.

Detailed Description of the Invention

The embodiments of the present invention described herein are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art can appreciate and understand the principles and practices of the present invention.

All publications and patents mentioned herein are hereby incorporated by reference. The publications and patents disclosed herein are provided solely for their disclosure. Nothing herein is to be construed as an admission that the inventors are not entitled to antedate any publication and/or patent, including any publication and/or patent cited herein.

Three dimensional ("3D") printing can be used to create a 3D solid object, such as from a digital model. The printer can deposit an at least partially liquid polymer material on a surface. The printer can add additional polymer material onto the surface or onto the already deposited polymer material to "build up" the solid object. The polymer, once deposited into place, can take time to dry, cure, or otherwise become rigid.

FIG. 1 is a perspective view of a 3D printed part 100. The printed part 100 can include the desired object 102 and a support structure 104. The user can desire to print the object 102. In some cases the geometry of the object 102 requires a support structure 104 to be printed along with the object 102. The support structure 104 can support a portion of the object 102, such as a projection, that requires time to become rigid. The projection could sag, bend or otherwise become deformed while drying or becoming rigid. The support structure 104 can hold the projection in place until the projection has become sufficiently rigid, such as to support itself.

Once the object 102 is sufficiently rigid, the support structure 104 can be removed. The support structure 104 can be removed such as by dissolving the support structure 104 or by cutting away the support structure 104. In an

embodiment, the object 102 can include different material than the support structure 104. In an embodiment, the object 102 can include polymer, such as acrylonitrile butadiene styrene ("ABS"). In an embodiment, the support structure 104 can include a soluble substance. In an embodiment, the support structure comprises an acrylic copolymer, such as a thermoplastic acrylic copolymer containing triphenyl phosphate. In some implementations the support structure comprises a terpolymer of methacrylic acid, styrene, and butylacrylate. In the alternative, a wax composition or blend can be used.

FIG. 2 shows the object 102 after the support structure 104 has been removed. After the support structure 104 has been removed, the object 102 can remain. The object 102 can be have been allowed sufficient time to dry, harden or otherwise become sufficiently rigid, such that the object 102 can support itself.

FIG. 3 shows a cross-section view of a 3D printed part 300. The printed part 300 can include the desired object 302 and a support structure 304. In an

embodiment, the object 302 can define an internal cavity 306, such as when the object is clamshell shaped (as shown in FIG. 3). At least a portion of the support structure 304 can be disposed within the internal cavity 306. The object 302 can define an aperture 308, such as to allow fluid communication between the internal cavity 306 and the exterior of the object 302. Fluid communication between the internal cavity 306 and the exterior of the object 302 can allow a solution access to the internal cavity 306, such as to dissolve the portion of the support structure 304 that is disposed within the internal cavity 306 while removing the support structure 304.

FIG. 4 shows a cross-section view of the object 302 after the support structure 304 has been removed, according to an embodiment. The support structure 304 can be dissolved. The printed part 300 have a solution applied to the support structure 304 to dissolve the support structure 304. In an embodiment, the support structure 304 includes different material than the object 302, such that the solution applied to dissolve the support structure 304 does not dissolve the object 302. The dissolved support structure 304 can be removed from the internal cavity 306, such as through the aperture 308.

In an embodiment, the solution for dissolving the support structure can include an electrolytic solution. In an embodiment, the electrolytic solution can include negatively reacted water or catholyte water. The electrolytic solution can have an ORP of -lOOmV to -1200mV. Note that in certain embodiments the catholyte has a negative initial ORP reading during manufacture, but over time this reading becomes positive. The electrolytic solution can have a pH of 9 to 14. The electrolytic solution can include the necessary chemical conditions to dissolve the support material without the addition of stripping chemistry that could damage the desired object. The electrolytic solution can have a rating of 1 or less on the Hazardous Materials

Identification System ("HMIS") chart.

FIG. 5 shows a perspective view of a system 500 to remove a support structure from a 3D printed part, according to an embodiment. The system 500 can include a cleaning vessel 502, such as a vessel where the electrolytic solution can be applied to the printed part to remove the support structure. The vessel 502 can define a cavity 504. The cavity 504 can at least partially be occupied by the electrolytic solution or the 3D printed part, when the system 500 is in use. An agitator 506 can be disposed of within the cavity 504, such as to agitate or recirculate the electrolytic solution. An agitator 506 can include a propeller or a recirculating pump. The vessel 502 can include a drain 508 to empty the electrolytic solution. The drain 508 can be coupled to a standard waste water drain. In other implementations the vessel 502 does not contain a drain, but is manually dumped.

The system 500 can include an external electrolytic water generator 510, such as a generator that produces electrolytic water. The external electrolytic water generator 510 can have a water input port 512. The water input port 512 can be coupled to a pipeline, such as to input water into the external electrolytic water generator 510. In an embodiment, standard city water or tap water can be input into the external electrolytic water generator 510.

The system 500 can include a transitional component 514, such as to transport the electrolytic solution from the electrolytic water generator 510 into the vessel 502. The transitional component 514 can be a pipe with a pump, a pipe that uses gravity to transport the electrolytic solution, or a container that a user fills and manually transports to the vessel 502.

FIG. 6 shows a flow chart of a method for removing a support structure from a 3D printer part after the part has been printed. The printed part can be placed into the vessel. An electrolytic solution can be created using standard city or tap water in an external electrolyte water generator and then transported into the vessel via a container or pipeline. The vessel can be at least partially filled with an electrolytic solution. In an embodiment, the printed part is placed into the vessel after the vessel has already been filled with the electrolytic solution. The printed part can be at least partially submerged in the electrolytic solution for a period of time, such as 15 minutes, 30 minutes, 1 hour, 2 hours, 4 hours, or 8 hours. The electrolytic solution can dissolve at least a portion of the support structure from the printed part, leaving the object intact. The object can then be removed from the vessel. In an

embodiment, the electrolytic solution is emptied from the vessel prior to the object being removed, such as through the drain. In an embodiment, the electrolytic solution and the dissolved support structure can be disposed of through a standard waste water drain.

FIG. 7 shows a perspective view of a system 700 to remove a support structure from a 3D printed part, according to an embodiment. The system 700 can include a cleaning vessel 702, such as a vessel where the electrolytic solution can be applied to the printed part to remove the support structure. The vessel 702 can define a cavity 704. The cavity 704 can at least partially be occupied by the electrolytic solution or the 3D printed part, when the system 700 is in use. An agitator 706 can be disposed of within the cavity 704, such as to agitate or recirculate the electrolytic solution. An agitator 706 can include a propeller or a recirculating pump. The vessel 702 can include a drain 708 to empty the electrolytic solution. The drain 708 can be coupled to a standard waste water drain.

The system 700 can include an internal electrolytic water generator 510, such as a generator that produces electrolytic water. The internal electrolytic water generator 710 can have a water input port 712. The water input port 712 can be coupled to a pipeline, such as to input water into the internal electrolytic water generator 710. In an embodiment, standard city water or tap water can be input into the internal electrolytic water generator 710.

In an embodiment, at least a portion of the internal electrolytic water generator

710 is at least partially disposed within the vessel 702. The internal electrolytic water generator 710 can include a discharge port 714, such as a port that discharges electrolytic water into the vessel to dissolve the support structure.

FIG. 8 shows a flow chart of a method for removing a support structure from a 3D printer part after the part has been printed. The printed part can be placed into the vessel. An electrolytic solution can be created using standard city or tap water in an internal electrolyte water generator and then discharged into the vessel. The vessel can be at least partially filled with an electrolytic solution. In an embodiment, the printed part is placed into the vessel after the vessel has already been filled with the electrolytic solution. The printed part can be at least partially submerged in the electrolytic solution for a period of time, such as 15 minutes, 30 minutes, 1 hour, 2 hours, 4 hours, or 8 hours. The electrolytic solution can dissolve at least a portion of the support structure from the printed part, leaving the object intact. The object can then be removed from the vessel. In an embodiment, the electrolytic solution is emptied from the vessel prior to the object being removed, such as through the drain. In an embodiment, the electrolytic solution and the dissolved support structure can be disposed of through a standard waste water drain.

FIG. 9 shows a perspective view of a system 900 to remove a support structure from a 3D printed part, according to an embodiment. The system 900 can include a cleaning vessel 902, such as a vessel where the electrolytic solution can be applied to the printed part to remove the support structure. The vessel 902 can define a cavity 904. The cavity 904 can at least partially be occupied by the electrolytic solution or the 3D printed part, when the system 900 is in use. An agitator 906 can be disposed of within the cavity 904, such as to agitate or recirculate the electrolytic solution. An agitator 906 can include a propeller or a recirculating pump. The vessel 902 can include a drain 908 to empty the electrolytic solution. The drain 908 can be coupled to a standard waste water drain.

The system 900 can include an electrolytic water generator 910, such as a generator that produces electrolytic water. The electrolytic water generator 910 can include a controller 914 and a probe 916. The controller 914 can be located external to the vessel 902. The probe 916 can be located inside the cavity 904. Standard city or tap water can be disposed in the vessel 102, such as through a fill port 912. The probe 916 can be at least partially inserted into the water, such as to convert the water to an electrolytic solution.

FIG. 10 shows a flow chart of a method for removing a support structure from a 3D printer part after the part has been printed. The printed part can be placed into the vessel, before the water is added, after the water is added or after the water is converted to an electrolytic solution. Standard city or tap water can be discharged into the vessel. The water can be converted to an electrolytic solution, such as with a probe that is inserted into the water. The vessel can be at least partially filled with an electrolytic solution. The printed part can be at least partially submerged in the electrolytic solution for a period of time, such as 15 minutes, 30 minutes, 1 hour, 2 hours, 4 hours, or 8 hours. The electrolytic solution can dissolve at least a portion of the support structure from the printed part, leaving the object intact. The object can then be removed from the vessel. In an embodiment, the electrolytic solution is emptied from the vessel prior to the object being removed, such as through the drain. In an embodiment, the electrolytic solution and the dissolved support structure can be disposed of through a standard waste water drain.

FIG. 11 shows a perspective view of a system 1100 to remove a support structure from a 3D printed part, according to an embodiment. The system 1100 can include a cleaning vessel 1102, such as a vessel where the electrolytic solution can be applied to the printed part to remove the support structure. The vessel 502 can define a cavity 504. The cavity 504 can at least partially be occupied by the electrolytic solution or the 3D printed part, when the system 500 is in use. An agitator 506 can be disposed of within the cavity 504, such as to agitate or recirculate the electrolytic solution. An agitator 506 can include a propeller or a recirculating pump. The vessel 502 can include a drain 508 to empty the electrolytic solution. The drain 508 can be coupled to a standard waste water drain.

Electrolytic solution can be added to the vessel 502. In an embodiment, a concentrate of electrolytic solution can be added to the vessel 502 and water can be added to dilute the concentrate. Water can be added through the water input port 1110. The water input port 1110 can input standard city or tap water. In an embodiment, the electrolytic solution or the electrolytic solution concentrate can be made off site and transported to the site of the system 1100.

FIG. 13 shows a flow chart of a method for removing a support structure from a 3D printer part after the part has been printed. The printed part can be placed into the vessel. An electrolytic solution can be added to the vessel before or after the printed part is placed into the vessel. In an embodiment, an electrolytic solution concentrate can be added to the vessel and diluted with water. The electrolytic solution can be created using standard city or tap water. The vessel can be at least partially filled with an electrolytic solution. The printed part can be at least partially submerged in the electrolytic solution for a period of time, such as 15 minutes, 30 minutes, 1 hour, 2 hours, 4 hours, or 8 hours. The electrolytic solution can dissolve at least a portion of the support structure from the printed part, leaving the object intact. The object can then be removed from the vessel. In an embodiment, the electrolytic solution is emptied from the vessel prior to the object being removed, such as through the drain. In an embodiment, the electrolytic solution and the dissolved support structure can be disposed of through a standard waste water drain.

FIG. 13 shows an electrolytic solution generator 1300. The electrolytic solution generator 1300 can generate an electrolytic solution from water, such as tap water. The electrolytic solution generator 1300 can include a water inlet 1302, such as an inlet that allows water to enter the electrolytic solution generator 1300. In an embodiment, the water inlet 1302 can be coupled to a water line, such as standard city water. The electrolytic solution generator 1300 can include a water softner 1304, such that the water can be softened, such as with NaCl. The electrolytic solution generator 1300 can include cathode 1306 and an anode 1310, with an ionic membrane disposed between. In an embodiment, the cathode 1306 can include titanium coated with iridium oxide. In an embodiment, the anode 1310 can include titanium coated with iridium oxide. After water is exposed to the cathode 1306 the water can become negative water. The negative water can be discharged out the negative water output 1312, such as to go into a vessel or to be transported to a vessel. After water is exposed to the anode 1310 the water can become positive water. The positive water can be discharged out the positive water output 1314, such as to a drain.

The electrolytic solution generator 1300 can include a rectifier 1316. The rectifier can be coupled to the cathode 1306. The rectifier can be coupled to the anode 1310. In an embodiment, the rectifier can send an electric current through the cathode 1306 and the anode 1310.

FIG. 14 is a view of a probe 1400 of an electrolytic solution generator, such as discussed in FIG. 9 and FIG. 10. The probe 1400 can include a mounting manifold 1402, such as to mount the probe 1400 to a vessel. The probe 1400 can include a water inlet 1404, such as where water enters a portion of the probe 1400. The probe 1400 can include a cathode 1406. The cathode 1406 can include titanium coated with iridium oxide. The cathode 1406 can be disposed in water, such as to convert the water to negative water. The probe 1400 can include an anode 1410. The anode 1410 can include titanium coated with iridium oxide coated with titanium. The probe 1400 can include an ionic membrane 1408 disposed between the cathode 1406 and the anode 1410. The probe 1400 can include a positive water outlet 1412, such as to discharge positive water out of the vessel.

It should be noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a composition containing "a compound" includes a mixture of two or more compounds. It should also be noted that the term "or" is generally employed in its sense including "and/or" unless the content clearly dictates otherwise.

It should also be noted that, as used in this specification and the appended claims, the phrase "configured" describes a system, apparatus, or other structure that is constructed or configured to perform a particular task or adopt a particular configuration to. The phrase "configured" can be used interchangeably with other similar phrases such as arranged and configured, constructed and arranged, constructed, manufactured and arranged, and the like.

All publications and patent applications in this specification are indicative of the level of ordinary skill in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated by reference.

The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention.

Claims

The Claims Are:

1. A method of creating an object, comprising:

printing a 3 -dimensional object with a printer, wherein the object is printed along with a removable support structure, wherein the removable support structure is configured to support at least a portion of the object while the object dries; and

removing the removable support structure by applying an electrolytic solution to the removable support structure.

2. The method of creating an object according to any of claims 1 and 3-11, wherein the electrolytic solution comprises catholyte water.

3. The method of creating an object according to any of claims 1-2 and 4-11, wherein applying an electrolytic solution comprises submerging the object and removable support structure into the electrolytic solution.

4. The method of creating an object according to any of claims 1-3 and 5-11, wherein the ORP of the electrolytic solution is at least -lOOmV and not more than - 1200mV.

5. The method of creating an object according to any of claims 1-4 and 6-11, wherein the pH of the electrolytic solution is at least 9 and not more than 14.

6. The method of creating an object according to any of claims 1-5 and 7-11, wherein the electrolytic solution has a rating of 1 or less on the Hazardous Materials Identification System ("HMIS") chart.

7. The method of creating an object according to any of claims 1-6 and 8-11, wherein the electrolytic solution is less than 80 °C.

8. The method of creating an object according to any of claims 1-7 and 9-11, wherein the electrolytic solution is less than 90 °C.

9. The method of creating an object according to any of claims 1-8 and 10-11, wherein the support structure comprises an acrylic copolymer.

10. The method of creating an object according to any of claims 1-9 and 11, wherein the electrolytic solution comprises a concentrate and water.

11. The method of creating an object according to any of claims 1-10, wherein the electrolytic solution is 90% or less water.

12. An apparatus for removing a support structure from a 3 dimensional printed object, comprising:

a vessel that defines a cavity and a drain;

the cavity is at least partially occupied by an electrolytic solution;

an agitating device disposed within the cavity; and

the cavity is configured for a 3 dimensional printed object to fit within.

13. The apparatus for removing a support structure from a 3 dimensional printed object according to any of claims 12 and 14-17, wherein the electrolytic solution comprises catholyte water.

14. The apparatus for removing a support structure from a 3 dimensional printed object according to any of claims 12-13 and 15-17, wherein the cavity is configured for the 3 dimensional printed object to be submerged in the electrolytic solution.

15. The apparatus for removing a support structure from a 3 dimensional printed object according to any of claims 12-14 and 16-17, wherein the ORP of the electrolytic solution is at least -lOOmV and not more than -1200mV.

16. The apparatus for removing a support structure from a 3 dimensional printed object according to any of claims 12-15 and 17, wherein the pH of the electrolytic solution is at least 9 and not more than 14.

17. The apparatus for removing a support structure from a 3 dimensional printed object according to any of claims 12-16, wherein the electrolytic solution has a rating of 1 or less on the Hazardous Materials Identification System ("HMIS") chart.

18. The apparatus for removing a support structure from a 3 dimensional printed object according to claim 12, wherein the electrolytic solution can at least partially dissolve a support structure that comprises an acrylic copolymer.

19. The apparatus for removing a support structure from a 3 dimensional printed object according to claim 12, wherein the electrolytic solution comprises a concentrate and water.