Method and system for additive manufacturing with a sacrificial structure for easy removal

A computer software product, comprising a computer-readable medium in which program instructions are stored, which instructions, when read by a computerized controller of an additive manufacturing system, cause said system to sequentially dispense and solidify a plurality of layers comprising:

• (i) one or more stacks of model layers arranged in configured patterns corresponding to shapes of one or more objects and being made of one or more modeling materials;
• (ii) an intermediate layer surrounding said shapes of one or more objects and comprising at least a support material;
• and
• (iii) a flexible overlay surrounding said intermediate layer, said stack of model layers being removable from said flexible overlay by separation along said first intermediate coating.

A system for fabricating a three-dimensional object by additive manufacturing, the system comprising:

• a plurality of dispensing heads, having at least a first dispensing head configured for dispensing at least one modeling material, a second dispensing head configured for dispensing a support material,
• a solidification system configured for solidifying each of said materials;
• and
• a computerized controller having a circuit configured for operating said dispensing heads and solidification system to sequentially dispense and solidify a plurality of layers comprising:
• (i) one or more stacks of model layers arranged in configured patterns corresponding to shapes of one or more objects and being made of one or more modeling materials;
• (ii) an intermediate layer surrounding said shapes of one or more objects and comprising at least one support material;
• and
• (iii) a flexible overlay surrounding said intermediate layer and being removable by separation at said first intermediate coating.