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<p>This paper provides a comprehensive review of the current state of soluble and breakaway support materials in material extrusion (MEX). Sec. 2 summarizes studies on solvent-soluble supports such as polyvinyl alcohol (PVA) and high-impact polystyrene (HIPS) and discusses their post-processing advantages as well as their limitations caused by low thermal resistance, with glass transition temperature (T<sub>g</sub>) of approximately 50 °C for PVA and 100 °C for HIPS. Sec. 3 reviews existing breakaway support designed for super engineering plastic (SEP). In Sec. 4, building on the findings of this review, a preliminary experimental study was performed to evaluate five thermoplastics, polyarylate (PAR), polysulfone (PSU), and three types of polycarbonate (PC), as potential breakaway supports for polyetheretherketone (PEEK)-MEX. PAR demonstrated stable structural performance and a low interfacial separation force of approximately 297 N, which is comparable to a commercial reference system (∼314 N), whereas the PC candidates (T<sub>g</sub> ≈ 150 °C) either collapsed during MEX or bonded too strongly to the model. These results suggest that PAR is a promising breakaway support material for PEEK. Finally, we propose challenges and directions for SEP-support in the future.</p>

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Exploration of breakaway support materials in high-temperature material extrusion: A mini-review and preliminary study

  • 期刊论文

  • 发表日期：

    2026年7月11日

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  • Han Bae,
  • Seungyun Lee,
  • Ji Eun Lee,
  • Seong Je Park,
  • Yong Son

摘要

This paper provides a comprehensive review of the current state of soluble and breakaway support materials in material extrusion (MEX). Sec. 2 summarizes studies on solvent-soluble supports such as polyvinyl alcohol (PVA) and high-impact polystyrene (HIPS) and discusses their post-processing advantages as well as their limitations caused by low thermal resistance, with glass transition temperature (Tg) of approximately 50 °C for PVA and 100 °C for HIPS. Sec. 3 reviews existing breakaway support designed for super engineering plastic (SEP). In Sec. 4, building on the findings of this review, a preliminary experimental study was performed to evaluate five thermoplastics, polyarylate (PAR), polysulfone (PSU), and three types of polycarbonate (PC), as potential breakaway supports for polyetheretherketone (PEEK)-MEX. PAR demonstrated stable structural performance and a low interfacial separation force of approximately 297 N, which is comparable to a commercial reference system (∼314 N), whereas the PC candidates (Tg ≈ 150 °C) either collapsed during MEX or bonded too strongly to the model. These results suggest that PAR is a promising breakaway support material for PEEK. Finally, we propose challenges and directions for SEP-support in the future.