# 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. - **Patent:** US 12358049 - **Original title:** Interface layers for removable supports - **Owner:** Desktop Metal - **Granted:** 2025 - **Status:** Active - **Times cited:** 1 - **Field:** additive_manufacturing, materials, mechanical, automotive, aerospace ## What it does 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. ## 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. ## 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. ## Real-world examples 1. Desktop Metal's Bound Metal Deposition (BMD) systems 2. Metal 3D printed tooling 3. Complex metal brackets with overhangs 4. Custom metal components for aerospace or medical devices ## Why it matters 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. ## 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. **Full plain-English explainer:** https://patentbrief.org/patent/us/12358049/interface-layers-for-removable-supports **Original patent:** https://patents.google.com/patent/US12358049 --- _Source: PatentBrief — https://patentbrief.org. Patent facts are from public records; the plain-English explanation is PatentBrief's._ ## Related patents Semantically similar inventions in the PatentBrief corpus: - [Building Metal Parts Without Melting: Solid-State 3D Printing System](https://patentbrief.org/patent/us/11311959/solid-state-additive-manufacturing-system-and-material-compositions-and-structur) — This patent describes a system for building or repairing metal parts by frictionally heating and stirring materials together without melting them, precisely controlling the material's internal structure as it's made. - [How to Improve 3D Printing Using Cold Spray Metal Deposition](https://patentbrief.org/patent/us/12233456/mars-colonial-transporter-architecture) — A method for perfecting metal 3D printing by analyzing how spray angles affect material quality and adjusting the printer's path to fix errors. - [How Machines Build 3D Objects Layer by Layer from Melting Plastic](https://patentbrief.org/patent/us/5121329/fdm-3d-printing-stratasys) — This patent describes a method and machine for creating three-dimensional objects by precisely depositing melted material, layer by layer, from a movable nozzle onto a base. - [How to Precisely Control Solid-State 3D Printing for Stronger Materials](https://patentbrief.org/patent/us/20240109245/process-control-systems-and-methods-using-a-solid-state-additive-manufacturing-s) — This patent describes a system for precisely controlling solid-state additive manufacturing, allowing real-time adjustments to create specific material structures without melting, using continuous material feeds. - [How 3D Printers Build Objects Layer by Layer from Liquid](https://patentbrief.org/patent/us/4575330/stereolithography-3d-printing) — This patent describes the foundational method for 3D printing, where a machine builds a three-dimensional object layer by layer by hardening a liquid material with light or other energy.