What’s the purpose of soluble support? Soluble support is typically used to make it easy to remove support material from complex geometries after printing. But its ability to dissolve on demand also makes it useful beyond traditional support structures.
For August’s Part of the Month, Field Service Technician and Purple Platypus University Instructor Jason Brown showcases a unique soluble support example: a carbon fiber part built around a Stratasys ST-130 soluble mold.
About The Part
Jason’s August pick is a perfect example of how soluble support can serve as more than just a temporary printing aid. It’s a real part used by Champion Motorsport for the Porsche 997 (the sixth generation of the Porsche 911). It is a turbo inlet duct, made by wrapping carbon fiber around ST-130 soluble support. Jason’s favorite aspect of the part is that the carbon fiber part remains intact after the soluble core is soaked out, leaving behind a perfectly dimensioned part. Jason explains how Champion uses carbon fiber to keep the inlet ducts “strong, thin, and lightweight.”
ST130 Soluble Support 3D Printed Mold
Carbon Fiber Composite Turbo Inlet Duct
About The Process
Champion Motorsport’s process starts by using a Stratasys Fortus printer to print a soluble core. That’s right – No standard material is used in this print, just support. After printing, the core is wrapped in carbon fiber, allowing the part to be manufactured as a single piece. Once the composite has cured, the core is dissolved away, leaving behind a smooth, precisely formed carbon fiber duct.
The one-piece construction improves consistency and performance, and as Champion’s Lead Mechanical Engineer, Tyson Lyew puts it, 3D printing provides “the magic recipe” for producing these soluble cores.
This method is called sacrificial tooling, and Jason notes that “this is the perfect name for the process.” Thanks to this soluble sacrifice, manufacturers can reduce lead times, minimize material waste, and create lighter-weight tooling.
About Stratasys ST-130
The soluble core was produced using Stratasys ST-130, a proprietary FDM material designed specifically for sacrificial tooling in composite manufacturing. Available on the Fortus 450mc and Fortus 900mc, ST-130 makes it possible to create complex internal molds that dissolve away after curing, allowing seamless carbon fiber parts that would be difficult or impossible to manufacture using traditional tooling.
Stratasys Fortus 450mc
Stratasys F900mc
About Sacrificial Tooling
3D printing makes it possible to produce composite lay-up tools in hours without the need for traditional tooling, even for complex geometries. Soluble cores can be printed with a sparse infill to save material and reduce costs, like the image below.
Jason compares the process to investment casting with one (big) key difference. Instead of removing a mold, the soluble support core dissolves away, leaving only the finished part. The disposable core speeds up production and enables complex, customized designs.
Sparse Soluble Core Example
Soluble Core Example
About Purple Platypus University
Jason is one of our experienced instructors here at Purple Platypus University, where we have the only Stratasys Authorized Training Center outside of Stratasys’ Minnesota headquarters.
Among other classes, Jason leads the FDM: Advanced Training – Stratasys Certified for AM Engineers course and helps users get the most out of their Stratasys systems. Jason covers composite lay-up tooling in this course, along with the following:
- FDM Technology Overview
- Materials & Applications
- Layer Thickness & Resolution
- File Types
- System Overview & Best Practices
- UI Navigation & Internal Components
- Hands-On System Training
- Build Chamber
- Purge Ledge
- Brush/Flicker Assembly
- Gantry/Head Area
- Identifying Tips
- Calibration
- Advanced FDM Modes
- GrabCAD Print: Advanced Software Overview
- Stabilizers
- Anchors
- Groups & Assemblies
- GrabCAD Print Pro Tools
- Insight: Software Deep Dive
- UI Navigation & Operations
- Build Styles & Toolpaths
- Custom Groups
- Tip Considerations
- Orientations
- Support Structures
- Stabilizing Walls
- Editing Slice Curves
- Metal Inserts
- General Maintenance & Troubleshooting
- Third-Party Certification
Whether you’re exploring sacrificial tooling for composite manufacturing or looking to sharpen your FDM skills, Purple Platypus University has you covered. Contact us to learn more about our training courses or how this process can fit into your workflow.
Meet Jason Brown
Meet our Field Service Technician and Purple Platypus University Instructor, Jason Brown. Jason supervises our machine operators and is responsible for maintaining our in-house printers. What Jason enjoys most about working at Purple is seeing so many amazing companies in a wide spectrum of industries, that all use 3D printing in their own unique way.
Out of the office, Jason enjoys surfing, snowboarding, downhill mountain bike racing, and spending time with his wife and kids. If you haven’t had the chance to meet Jason, make sure to connect with him on LinkedIn!
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