# US 11,298,885 B2 · Three-dimensionally article with knock out support defined with build material

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- Number: US 11,298,885 B2
- Document ID: US11298885B2
- Status: Granted
- Kind: B2
- Application number: 16/682,396
- Filed: 2019-11-13
- Published: 2020-05-14
- Granted: 2022-04-12
- Earliest claimed: 2018-11-14
- Assignees: 3D Systems, Inc.
- Applicants: 3D Systems, Inc.
- Inventors: Colin Leonard Blain
- Web page: https://patentgrep.com/patent/US11298885B2

## CPC

- B29C 64/245: Platforms or substrates (support structures intended to be sacrificed after manufacture B29C64/40)
- B22F 10/47: characterised by structural features
- B22F 10/80: Data acquisition or data processing
- B29C 64/10: Processes of additive manufacturing
- B29C 64/393: for controlling or regulating additive manufacturing processes
- B29C 64/40: Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
- B29D 22/00: Producing hollow articles (tubular articles B29D23/00; pneumatic tyres B29D30/00)
- B33Y 50/00: Data acquisition or data processing for additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- B22F 3/11: Making porous workpieces or articles
- B22F 5/10: of articles with cavities or holes, not otherwise provided for in the preceding subgroups
- B22F 10/12: by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP]
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- B29C 64/112: using individual droplets, e.g. from jetting heads
- B29C 64/124: using layers of liquid which are selectively solidified
- B29C 64/386: Data acquisition or data processing for additive manufacturing
- B29L 2022/00: Hollow articles (tubular articles B29L2023/00; pneumatic tyres B29L2030/00)
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 40/00: Auxiliary operations or equipment, e.g. for material handling
- B33Y 50/02: for controlling or regulating additive manufacturing processes
- Y02P 10/25: Process efficiency
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A method of manufacturing a three-dimensional article includes (1) receiving a data file, (2) analyzing the data file, and (3) defining a support structure. The data file defines a hollow three-dimensional article to be formed from a build material. Analyzing the data file includes identifying an opening that converges to an apex along the sequence of layers. The opening is at least partly defined by an inside edge of the three-dimensional article. The support structure is attached to the edge and closes the opening. The support structure includes a structural sheet portion and an interface web portion. The structure sheet portion defines a majority of an area of the support structure except for a boundary contour between the structural sheet portion and the inside edge. The interface web portion closes the boundary contour and defines a weakness contour for removing the structural portion from the three-dimensional article.

## Claims

### Claim 1

A method of manufacturing a three-dimensional article with a sequence of layers comprising:
receiving a data file defining a hollow three-dimensional article to be formed from a build material;
analyzing the data file to identify an opening that converges to an apex along the sequence of layers, the opening defined by a perimeter edge of the three-dimensional article that extends at least partly in a vertical direction; and
defining a support structure attached to the perimeter edge that closes the opening including:
a structural sheet portion that defines a majority of an area of the support structure except for a boundary contour between the structural sheet portion and the perimeter edge; and
an interface web portion that substantially closes the boundary contour and defines a weakness contour for removing the structural sheet portion; and
printing the article with the attached support structure.

### Claim 2 (depends on 1)

The method of claim 1 wherein the perimeter edge completely bounds the opening.

### Claim 3 (depends on 1)

The method of claim 1 wherein a combination of the perimeter edge and a support tray or plate bounds the opening.

### Claim 4 (depends on 1)

The method of claim 1 wherein the three-dimensional article has a model thickness along the perimeter edge, the structural sheet has a sheet thickness of at least 30% of the model thickness along the perimeter edge.

### Claim 5 (depends on 1)

The method of claim 1 wherein the structural sheet has a sheet thickness, the interface web portion has a thickness that is less than 50% of the sheet thickness.

### Claim 6 (depends on 1)

The method of claim 1 wherein the article with the attached support structure is formed from a single build material using a stereolithographic process.

### Claim 7 (depends on 6)

The method of claim 6 further comprising impacting the structural sheet material to sever the support from the three-dimensional article along the weakness contour.

### Claim 8

A computer-readable storage medium for manufacturing a three-dimensional article with a sequence of layers, the computer readable storage medium being non-transitory and storing software instructions that in response to execution by a processor cause a three-dimensional printing system to:
receive a data file defining a hollow three-dimensional article to be formed from a build material;
analyze the data file to identify an opening that converges to an apex along the sequence of layers, the opening defined by a perimeter edge of the three-dimensional article that extends at least partly in a vertical direction; and
define a support structure attached to the perimeter edge that closes the opening including:
a structural sheet portion that defines a majority of an area of the support structure except for a boundary contour between the structural sheet portion and the perimeter edge; and
an interface web portion that substantially closes the boundary contour and defines a weakness contour for removing the structural sheet portion; and
operate a print engine to fabricate the three-dimensional article and the support structure.

### Claim 9 (depends on 8)

The computer-readable storage medium of claim 8 wherein the perimeter edge completely bounds the opening.

### Claim 10 (depends on 8)

The computer-readable storage medium of claim 8 wherein a combination of the perimeter edge and a support tray or plate bounds the opening.

### Claim 11 (depends on 8)

The computer-readable storage medium of claim 8 wherein the three-dimensional article has a model thickness along the perimeter edge, the structural sheet has a sheet thickness of at least 30% of the model thickness along the perimeter edge.

### Claim 12 (depends on 8)

The computer-readable storage medium of claim 8 wherein the structural sheet has a sheet thickness, the interface web portion has a thickness that is less than 50% of the sheet thickness.

### Claim 13 (depends on 8)

The computer-readable storage medium of claim 8 wherein the print engine is operated to fabricate the three-dimensional article and the support structure from a single build material using a stereolithographic process.

### Claim 14

A three-dimensional printing system for manufacturing a three-dimensional article with a sequence of layers, the three-dimensional printing system including:
a print engine for fabricating the three-dimensional article; and
a controller for controlling the print engine and including a processor coupled to a non-transitory storage medium, the non-transitory storage medium storing software instructions that, when executed by the processor, perform the following steps:
receive a data file defining a hollow three-dimensional article to be formed from a build material;
analyze the data file to identify an opening that converges to an apex along the sequence of layers, the opening defined by a perimeter edge of the three-dimensional article that extends at least partly in a vertical direction; and
define a support structure attached to the perimeter edge that closes the opening including:
a structural sheet portion that defines a majority of an area of the support structure except for a boundary contour between the structural sheet portion and the perimeter edge; and
an interface web portion that substantially closes the boundary contour and defines a weakness contour for removing the structural sheet portion; and
operate the print engine to fabricate the three-dimensional article.

### Claim 15 (depends on 14)

The three-dimensional printing system of claim 14 wherein the perimeter edge completely bounds the opening.

### Claim 16 (depends on 14)

The three-dimensional printing system of claim 14 wherein a combination of the perimeter edge and a support tray or plate bounds the opening.

### Claim 17 (depends on 14)

The three-dimensional printing system of claim 14 wherein the three-dimensional article has a model thickness along the perimeter edge, the structural sheet has a sheet thickness of at least 30% of the model thickness along the perimeter edge.

### Claim 18 (depends on 14)

The three-dimensional printing system of claim 14 wherein the structural sheet has a sheet thickness, the interface web portion has a thickness that is less than 50% of the sheet thickness.

### Claim 19 (depends on 14)

The three-dimensional printing system of claim 14 wherein the print engine is operated to fabricate the three-dimensional article using a stereolithographic process.

### Claim 20 (depends on 19)

The three-dimensional printing system of claim 19 wherein the three-dimensional article and the support structure are formed from the same build material.