3D Printed Composite Structure for Flexible Shock Absorption
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Solution Overview
Problem
Existing 3D printed structures are often stiff due to the materials used, making them inflexible and challenging to achieve both compressibility and structural integrity, especially in applications requiring individualization and flexibility, such as in the aerospace industry.
Innovation Solution
A 3D printed structure comprising layers with varying rigidity, where primary structural layers and flexible layers are arranged to intersect at different angles, allowing for a resilient mechanical interaction that absorbs forces and returns to original shape, enabling predictable deformation and maintaining counterforce.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If foam-like flexible materials are used to provide flexibility and compressibility, then the structure becomes more flexible and comfortable, but the structural strength decreases and weight increases
Solution Approach 1:
The patent combines rigid 3D-printed structural layers with flexible foam layers to create a composite structure. The rigid layers provide structural strength and shape retention, while the flexible foam layers provide comfort and compressibility. This composite approach resolves the contradiction by integrating materials with complementary properties rather than relying on a single material type.
Solution Approach 2:
The patent applies different material properties to different regions of the product. Rigid 3D-printed layers are positioned where structural support is needed, while flexible foam layers are positioned where comfort and flexibility are required. This local differentiation allows the structure to simultaneously achieve both strength and flexibility in appropriate locations.
2Productivity
If traditional molding methods are used for flexible layers, then mass production is efficient, but individualization and customization require expensive additional molds
Solution Approach 1:
The patent utilizes 3D printing technology to vary structural parameters (such as layer thickness, density, and geometry) directly during manufacturing based on digital models. This allows customization of each layer's properties without requiring physical mold changes, enabling both mass production efficiency and individualization capability.
Solution Approach 2:
The patent creates physical structures from digital 3D models, allowing easy replication and customization through software modifications rather than physical mold changes. The digital blueprint can be copied and modified to create individualized products while maintaining manufacturing efficiency through automated 3D printing processes.
3Ease of operation
If more flexible material is used to increase compressibility, then the structure becomes more comfortable, but the counterforce to maintain structural integrity decreases
Solution Approach 1:
The patent combines flexible foam materials with rigid 3D-printed structural layers to create a composite structure. The flexible foam provides compressibility and comfort by deforming under load, while the rigid structural layers maintain overall shape and provide counterforce to prevent collapse. This composite approach allows the structure to be both compressible and structurally sound.
Solution Approach 2:
The patent divides the structure into multiple layers with different functions: flexible foam layers for comfort and compression, and rigid structural layers for support and shape retention. This segmentation allows each layer to perform its specialized function, with the flexible layers providing compressibility and the rigid layers providing counterforce.
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
The structure achieves a balance between flexibility and structural integrity by allowing specific areas to deform predictably under compressive forces while maintaining resistance, suitable for applications like shoe midsoles and shock absorption.
Implementation Method 1
a 3D printed structure of an elastic material having at least a first layer and a second layer
Data Source
AI summary
A 3D printed structure of an elastic material having at least a first layer and a second layer may be provided. In one implementation, the 3D printed structure may include at least a first wall having a primary structural layer and a first flexible layer, and at least a second wall having a secondary structural layer and a second flexible layer. An axis of the 3D printed structure may intersect the first layer and the second layer and may intersect the primary structural layer and the secondary structural layer. The primary structural layer may have a first rigidity and the first flexible layer may have a second rigidity, the first rigidity being greater than the second rigidity.