Structure supporting an object during additive manufacturing and method for forming

Abstract

A supporting structure built together with an object in an additive manufacturing (AM) process and configured to support an overhang of the object is described. The supporting structure includes a first array of pillars formed with a first material and reinforced with a second material. Each of the pillars in the first array includes a top. At least a portion of the tops in the first array adjoin and define a surface on which the overhang of the object may be supported. The first material is support material.

What is claimed is: 
     
         1 . A supporting structure for supporting an overhang of an object during additive manufacturing, the supporting structure comprising:
 a plurality of object-supporting pillars, each being formed of a support material and reinforced with a reinforcing material;   wherein at least a portion of said object-supporting pillars adjoin at tops thereof and define a surface supporting the overhang of the object.   
     
     
         2 . The supporting structure of  claim 1 , comprising a contact pad formed of said support material and configured to interface with the overhang of the object. 
     
     
         3 . The supporting structure of  claim 1 , wherein a cross-section of each object-supporting pillar is wider at said top thereof than at a base thereof. 
     
     
         4 . The supporting structure of  claim 1 , wherein said object-supporting pillars defines an array of air pockets shaped as spires. 
     
     
         5 . The supporting structure of  claim 1 , comprising a plurality of pillar-supporting pillars adjoined at tops thereof such that said adjoined tops of said pillar-supporting pillars support bases of said object-supporting pillars. 
     
     
         6 . The supporting structure of  claim 5 , wherein said tops of said pillar-supporting pillars are larger in size than said tops of said object-supporting pillars, such that at least two bases of object-supporting pillars are supported by a top of a single pillar-supporting pillar. 
     
     
         7 . The supporting structure of  claim 5 , wherein at least a portion of said pillar-supporting pillars are larger in size than each of said object-supporting pillars. 
     
     
         8 . The supporting structure of  claim 1 , wherein the support material is a liquid-soluble thermoplastic. 
     
     
         9 . The supporting structure of  claim 1 , wherein the reinforcing material is a photopolymer. 
     
     
         10 . The supporting structure of  claim 1 , wherein the supporting structure is formed by inkjet printing. 
     
     
         11 . A method of supporting an overhang in an object during additive manufacturing (AM) of the object, the method being executed by an AM system and comprising:
 building a plurality of object-supporting pillars from a support material, such that at least a portion of said object-supporting pillars adjoin at tops thereof;   building reinforcements around said object-supporting pillars from a reinforcing material; and   building the overhang on said adjoined tops.   
     
     
         12 . The method of  claim 11 , comprising, building a contact pad between said adjoined tops and the overhang. 
     
     
         13 . The method of  claim 11 , wherein said reinforcing material is a model material with which the object is built. 
     
     
         14 . The method of  claim 11 , comprising, prior to said building of said plurality of object-supporting pillars, building a plurality of pillar-supporting pillars adjoined at tops thereof, wherein said building of said plurality of object-supporting pillars is onto said adjoined tops of said pillar-supporting pillars. 
     
     
         15 . The method of  claim 11 , comprising, building reinforcements around said pillar-supporting pillars using said reinforcing material. 
     
     
         16 . The method of  claim 14 , wherein said tops of said pillar-supporting pillars are larger in size than said tops of said object-supporting pillars, such that at least two bases of object-supporting pillars are supported by a top of a single pillar-supporting pillar. 
     
     
         17 . The method of  claim 14 , wherein at least a portion of said pillar-supporting pillars are larger in size than each of said object-supporting pillars. 
     
     
         18 . The method of  claim 11 , wherein said building said plurality of object-supporting pillars is such as to form an array of air pockets shaped as spires therebetween. 
     
     
         19 . The method of  claim 11 , wherein the AM system is configured for inkjet printing. 
     
     
         20 . An additive manufacturing (AM) system comprising:
 a plurality of arrays of nozzles for dispensing support material and model material;   a computerized controller, configured to control said arrays of nozzles to execute the method according to  claim 11 .