3D Printer Infill Transition Layers for Faster Stable Printing
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Solution Overview
Problem
3D printing of interior infills is slow and prone to inaccuracies, particularly in fused deposition modeling, leading to irregular tactile feeling and compressive properties, especially when external forces are applied.
Innovation Solution
A method involving a first and second infill pattern with different general directions and a transitional infill pattern with increased cross-sectional width to enhance bonding and stability, ensuring even distribution of compressive forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If printing speed is increased to reduce manufacturing time, then productivity improves, but manufacturing precision deteriorates due to inaccuracies in deposited material
Solution Approach 1:
The patent applies parameter changes by systematically varying the infill pattern geometry (waveform shape, cross-sectional width, spacing between lines) and printing parameters (speed, temperature, layer height) to optimize both printing speed and accuracy. The waveform infill pattern with specific amplitude and wavelength parameters enables faster printing while maintaining structural integrity and dimensional accuracy.
2Productivity
If infill pattern lines are spaced further apart to reduce printing time, then productivity improves, but reliability deteriorates due to reduced stability under external forces
Solution Approach 1:
The patent employs curved waveform patterns instead of straight lines for the infill structure. The sinusoidal or波浪-shaped lines distribute mechanical stresses more effectively across the infill material, providing enhanced stability and load-bearing capacity even when lines are spaced further apart to reduce printing time.
3Device complexity
If a single infill pattern direction is used to simplify the printing process, then device complexity is reduced, but strength deteriorates because the infill collapses under applied forces
Solution Approach 1:
The patent introduces asymmetric or multi-directional waveform patterns where successive layers or regions have infill lines oriented at different angles or with varying waveform characteristics. This asymmetric approach prevents collapse under applied forces by distributing stress across multiple orientations while maintaining relatively simple printing process control.
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
Improves printing speed and stability of interior infills by efficiently bonding layers, maintaining hardness properties, and ensuring even compression without visible inaccuracies.
Implementation Method 1
Additive manufacturing, also referred to as 3D printing, enables rapid prototyping and the ability of producing complex shapes and geometries
Implementation Method 2
the commonly used 3D printing technique of fused deposition modelling, in which a continuous filament is deposited via a heated printer head
Data Source
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AI summary
The invention relates to a method of printing an interior infill using a 3D printer. The method comprises the steps of: defining a planar first infill pattern (11) of lines having a first cross-sectional width; defining a planar second infill pattern (12) of lines having a second cross-sectional width; defining a planar transitional infill pattern (13) of lines having a third cross-sectional width exceeding the first cross-sectional width and the second cross-sectional width; and printing a first set of layers of the first infill pattern, a transitional set of layers of the transitional infill pattern, and a second set of layers of the second infill pattern such that the transitional set of layers is printed between the first set of layers and the second set of layers. The invention further relates to an article having a layered interior infill and a computer system for designing an interior infill of an article.