Inorganic ionic support materials for digital manufacturing systems
A support material for use with a digital manufacturing system, the support material comprising at least one inorganic ionic compound and is configured to be deposited with the digital manufacturing system using a layer-based additive technique to form a support structure for supporting at least one overhanging region of a three-dimensional model built with the digital manufacturing system.
1. A method for building a three-dimensional model with a digital manufacturing system, the method comprising:
heating a build chamber of the digital manufacturing system to maintain one or more temperatures of at least about 200° C.;
melting a support material in an extrusion head of the digital manufacturing system to an extrudable state, wherein the support material comprises a non-eutectic blend of a first inorganic alkali-metal salt and a second inorganic alkali-metal salt;
extruding the molten support material from the extrusion head;
depositing the extruded support material into the heated build chamber using a first layer-based additive technique to form a support structure; and
depositing a modeling material into the heated build chamber using a second layer-based additive technique to form the three-dimensional model, wherein the three-dimensional model comprises at least one overhanging region supported by the support structure.
2. The method of claim 1 , wherein the first inorganic alkali-metal salt comprises lithium chloride.
3. The method of claim 1 , wherein heating the build chamber comprises heating the build chamber to maintain one or more temperatures ranging from about 400° C. to about 700° C.
4. The method of claim 1 , wherein the support material has an average creep relaxation temperature that is within about 30° C. of a creep relaxation temperature of the modeling material.
5. The method of claim 1 , and further comprising removing at least a portion of the support structure from the three-dimensional model by dissolving the portion of the support structure in a liquid.
6. The method of claim 1 , and further comprising substantially purging the build chamber of oxidizing gases.
7. The method of claim 1 , wherein the second inorganic alkali-metal salt comprises potassium chloride.
8. The method of claim 1 , wherein the non-eutectic blend constitutes from about 75% by weight to 100% by weight of the support material.
9. The method of claim 1 , and further comprising recycling at least a portion of the deposited support material.
10. A method for building a three-dimensional model with a digital manufacturing system, the method comprising:
heating a build chamber of the digital manufacturing system to maintain one or more temperatures of at least about 200° C.;
melting a support material in an extrusion head of the digital manufacturing system to an extrudable state, wherein the support material comprises a non-eutectic blend of a first alkali-metal salt and a second alkali-metal salt, and wherein the support material is substantially free of organic compounds;
extruding the molten support material from the extrusion head;
depositing the extruded support material into the heated build chamber using a first layer-based additive technique to form a support structure; and
depositing a modeling material into the heated build chamber using a second layer-based additive technique to form the three-dimensional model, wherein the three-dimensional model comprises at least one overhanging region supported by the support structure.
11. The method of claim 10 , wherein the first alkali-metal salt comprises lithium chloride.
12. The method of claim 10 , wherein heating the build chamber comprises heating the build chamber to maintain one or more temperatures ranging from about 400° C. to about 700° C.
13. The method of claim 10 , wherein the second alkali-metal salt comprises potassium chloride.
14. The method of claim 10 , wherein the non-eutectic blend constitutes from about 75% by weight to 100% by weight of the support material.
15. A method for building a three-dimensional model with a digital manufacturing system, the method comprising:
heating a build chamber of the digital manufacturing system to maintain one or more temperatures ranging from about 400° C. to about 700° C.;
melting a support material in an extrusion head of the digital manufacturing system to an extrudable state, wherein the support material comprises a non-eutectic blend of potassium chloride and lithium chloride;
extruding the molten support material from the extrusion head;
depositing the extruded support material into the heated build chamber using a first layer-based additive technique to form a support structure; and
depositing a modeling material into the heated build chamber using a second layer-based additive technique to form the three-dimensional model, wherein the three-dimensional model comprises at least one overhanging region supported by the support structure, and wherein the modeling material comprises a metal-based material.
16. The method of claim 15 , wherein the potassium chloride constitutes from about 60% by weight to about 99% by weight of the non-eutectic blend.
17. The method of claim 16 , wherein the potassium chloride constitutes from about 70% by weight to about 95% by weight of the non-eutectic blend.
18. The method of claim 15 , wherein the metal-based material of the modeling material comprises a non-eutectic, metal-based alloy.
19. The method of claim 15 , wherein the lithium chloride constitutes from about 50% to about 99% of the non-eutectic blend.
20. The method of claim 15 , wherein the lithium chloride constitutes from about 65% to about 90% of the non-eutectic blend.