How to 3D Print Metal Parts with Easy-to-Remove Supports
This patent describes a method for 3D printing complex metal objects with support structures that can be easily removed after the final part is made solid, by using a special non-stick layer in between.
Original patent title: “Interface layers for removable supports”
This patent describes a method for 3D printing complex metal objects with support structures that can be easily removed after the final part is made solid, by using a special non-stick layer in between. Granted to Desktop Metal in 2025 with 20 claims and 1 forward citation, and it is expected to expire in 2044.
Coverage
What does this patent actually cover?
The patent details a method for 3D printing metal objects and their support structures layer by layer (ClaimclaimA numbered sentence at the end of a patent that legally defines what the inventor owns. The most important section.Read more → 1). The "build material" is a mix of metal powder and a "binder system" (Claim 1). Crucially, a special "interface of non-sinterable material" is printed between the object and its supports (Claim 1). After printing, a "debinding" step removes the binder, and then "sintering" heats the parts, making them solid and dense (Claim 1). Because of the non-sinterable interface, the support structure can be easily separated from the finished metal object, sometimes with a simple mechanical force (Claim 13). For example, printing a metal bracket with an overhang would require supports, and this method ensures those supports don't fuse to the bracket during the final hardening step.
The gap
What does this patent NOT cover?
- Does not cover 3D printing processes that do not involve a sintering step for densification of the final object.
- Does not cover support removal methods where the support and object are made of the exact same sinterable material throughout.
- Does not cover 3D printing of non-metallic objects, as the claimsclaimsThe numbered statements at the end of a patent that legally define what the inventor owns.Read more → specify a "metallic three-dimensional object" (ClaimclaimA numbered sentence at the end of a patent that legally defines what the inventor owns. The most important section.Read more → 1).
- Does not cover methods where the interface material itself sinters and bonds to the object or support.
- Does not cover support structures that are dissolved or melted away without the use of a non-sinterable interface.
These exclusions are unique to PatentBrief — derived from the actual claim language, not patent-office boilerplate.
Key facts
What made this novel
The noveltynoveltyThe requirement that an invention be different from anything publicly known before its priority date.Read more → lies in strategically placing a "non-sinterable material" as an interface layer between the object and its support structure. This prevents the object and support from fusing together during the high-temperature "sintering" process, allowing for simple, damage-free separation afterwards.
The Patent Drawing
Schematic visualization of the patent's claim structure. Hand-drawn diagrams in progress for each landmark patent.
Where you've seen this
Real-world examples
Desktop Metal's Bound Metal Deposition (BMD) systems
Metal 3D printed tooling
Complex metal brackets with overhangs
Custom metal components for aerospace or medical devices
Why it matters
The bigger picture
Additive manufacturing, especially with metals, often requires support structures for complex shapes. Removing these supports from fully dense metal parts can be difficult and costly, sometimes damaging the finished object. This patent addresses that challenge by making support removal much easier and cleaner, which can reduce post-processing time and improve part quality. This is particularly important for industries adopting metal 3D printing for functional parts.
Filed
March 20, 2024
Granted
July 15, 2025
Market context
Who's building on this
Companies in this space
Desktop Metal Inc., the assigneeassigneeThe entity that owns the patent — usually the inventor's employer or a company.Read more →, is a prominent company in the metal additive manufacturing space, developing and selling systems that utilize processes like "Bound Metal Deposition" which align with the methods described. Other companies in the metal binder jetting and extrusion 3D printing sectors are also working on similar challenges related to support removal.
Market impact
This patent addresses a significant bottleneck in metal additive manufacturing: the difficulty and cost of removing support structures from complex geometries. By enabling easier, damage-free support removal, it can lower the overall cost of producing metal 3D printed parts, making the technology more accessible and competitive for industrial applications. This could expand the range of economically viable parts for industries like automotive, aerospace, and medical devices.
Claim 1 — Plain English
What this patent covers
The patent details a method for 3D printing metal objects and their support structures layer by layer (Claim 1). The "build material" is a mix of metal powder and a "binder system" (Claim 1). Crucially, a special "interface of non-sinterable material" is printed between the object and its supports (Claim 1). After printing, a "debinding" step removes the binder, and then "sintering" heats the parts, making them solid and dense (Claim 1). Because of the non-sinterable interface, the support structure can be easily separated from the finished metal object, sometimes with a simple mechanical force (Claim 13). For example, printing a metal bracket with an overhang would require supports, and this method ensures those supports don't fuse to the bracket during the final hardening step.
The clever bit
The novelty lies in strategically placing a "non-sinterable material" as an interface layer between the object and its support structure. This prevents the object and support from fusing together during the high-temperature "sintering" process, allowing for simple, damage-free separation afterwards.
What it does not cover
- Does not cover 3D printing processes that do not involve a sintering step for densification of the final object.
- Does not cover support removal methods where the support and object are made of the exact same sinterable material throughout.
- Does not cover 3D printing of non-metallic objects, as the claims specify a "metallic three-dimensional object" (Claim 1).
- Does not cover methods where the interface material itself sinters and bonds to the object or support.
- Does not cover support structures that are dissolved or melted away without the use of a non-sinterable interface.
Patent timeline
Application submitted to the patent office
Application published, typically 18 months after filing
Patent officially issued
Patent enters public domain
PatentBrief Score
Impact Score
Moderate
Citation count
6/40
Early citations
Claim breadth
13/20
Broad claimsclaimsThe numbered statements at the end of a patent that legally define what the inventor owns.Read more →
Recency
20/20
Granted within 5 years
Assignee scale
20/20
Major company or institution
PatentBrief Impact Score — based on citation count, claim breadth, recency, and assignee scale. Not a legal assessment.
Heuristic Value Estimate
What this patent might be worth
$35K – $112K
Midpoint $70K · 17.6 yr remaining · industry ×0.9
Heuristic only — blends forward/backward citation counts, claim scope, time remaining, litigation history, and CPC-derived industry baseline. Real valuations need a professional appraisal.
Claim text not yet imported for this patent
The original legal language
Original claims
20 claims as filed with the patent office.
Concepts involved
Citations
Patent lineage
Cite this patent
Verminski, M. D., Fulop, R., Chiang, Y., Hart, A. J., Myerberg, J. S., Gibson, M. A., Schuh, C. A., & Fontana, R. R. (2025). How to 3D Print Metal Parts with Easy-to-Remove Supports (U.S. Patent No. 12,358,049). U.S. Patent and Trademark Office. https://patentbrief.org/patent/us/12358049/interface-layers-for-removable-supports
Auto-generated from the patent record. Double-check author order and the issue date against the official USPTO document before submitting.
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Common Questions
Frequently Asked Questions
What does How to 3D Print Metal Parts with Easy-to-Remove Supports cover?
This patent describes a method for 3D printing complex metal objects with support structures that can be easily removed after the final part is made solid, by using a special non-stick layer in between.
Who owns patent US 12358049?
Desktop Metal owns this patent, granted in 2025.
When does this patent expire?
This patent is expected to expire on March 20, 2044, when the invention enters the public domain.
What is patent US 12358049 cited by?
This patent has been cited by 1 later patents that build on its ideas.
What problem does this patent solve?
Additive manufacturing, especially with metals, often requires support structures for complex shapes. Removing these supports from fully dense metal parts can be difficult and costly, sometimes damaging the finished object. This patent addresses that challenge by making support removal much easier and cleaner, which can reduce post-processing time and improve part quality. This is particularly important for industries adopting metal 3D printing for functional parts.
What does this patent NOT cover?
Does not cover 3D printing processes that do not involve a sintering step for densification of the final object.
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