3D Printed Luminaire Fixture Mesh Structure Against Warpage
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Solution Overview
Problem
3D printed lighting fixtures face challenges with warpage and delamination due to stress-induced deformations from material shrinkage during cooling, leading to mechanical instability and integrity issues.
Innovation Solution
A design rule is applied in 3D printing that balances solid and meshed wall parts in each layer, with the sum of meshed wall part perimeters exceeding the solid wall part perimeters, to mitigate stress accumulation and improve mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If meshed wall parts are used to reduce stress accumulation, then mechanical stability improves, but structural strength decreases
Solution Approach 1:
The patent combines meshed wall parts and solid wall parts within the same fixture structure. The meshed portions break stress accumulation while the solid portions provide structural strength, achieving a synergistic effect where the whole performs better than the sum of its parts.
Solution Approach 2:
Different regions of the fixture are assigned different wall structures based on local requirements. Meshed wall parts are placed in regions prone to stress accumulation, while solid wall parts are placed in regions requiring structural strength, optimizing both stability and strength locally.
2Strength
If solid wall parts are used to ensure mechanical robustness, then structural strength improves, but warpage and delamination increase
Solution Approach 1:
The continuous solid wall structure is segmented into discrete wall segments separated by gaps, forming a meshed structure. This segmentation interrupts the propagation path of internal stresses, preventing warpage and delamination while maintaining overall structural integrity.
Solution Approach 2:
The patent converts the potentially harmful effect of stress accumulation into a beneficial feature by using the meshed structure to deliberately break and redirect stress paths, transforming what would be a weakness into a stress-mitigation mechanism.
3Productivity
If meshed wall parts are used to reduce material usage, then productivity improves, but manufacturing precision decreases
Solution Approach 1:
Solid wall parts are strategically placed in regions requiring high precision for non-printed components such as fitting edges, guidance features, and closures. Meshed wall parts are used in regions where material efficiency is prioritized, achieving local optimization of both precision and productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the risk of warpage and delamination, enhances mechanical stability, and allows for improved air circulation and thermal management while maintaining structural integrity.
Implementation Method 1
stresses may be induced between subsequent layers as the molten material starts to cool down and solidify. The stresses have been observed to be closely related to the material shrinking during the cooling and/or solidification process.
Data Source
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AI summary
A 3D printed fixture (100) for a luminaire is provided. The 3D printed fixture comprises at least one meshed wall part (110) and at least one solid wall part, wherein the meshed wall part further comprises a plurality of wall segments (112) defining a plurality of apertures (114) extending through the meshed wall part. The solid wall part and the meshed wall part are formed by a plurality of layers (130) stacked on each other in a stacking direction. Each layer forms cross sectional portions (116) of the plurality of wall segments of the meshed wall part and a cross-sectional portion (126) of the solid wall part. For each layer, the sum of the perimeters of the cross-sectional portions of the plurality of wall segments exceeds the perimeter of the cross-sectional portion of the solid wall part.