3D Printed Grid Structures for Tuned Mechanical Properties
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Solution Overview
Problem
Existing methods for manufacturing three-dimensional objects with specific internal structures are limited in generating objects with diverse mechanical properties, particularly flexibility and rigidity, using traditional building materials.
Innovation Solution
A method that calculates grid structures based on material properties to create objects with desired mechanical characteristics, such as elasticity and rigidity, by layer-wise building using powdery materials like polyamide or PEBA, allowing for the creation of objects with unique combinations of properties not achievable in massive forms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If elastomer powders are used for laser sintering to create flexible parts, then flexibility is improved, but the application area is restricted and material options are limited
Solution Approach 1:
The patent changes the structural parameters of the object by introducing grid structures with varying cell sizes, shapes, and wall thicknesses. This allows rigid materials to exhibit flexible characteristics through structural design rather than material selection, expanding material options while maintaining versatility
Solution Approach 2:
The patent creates composite structures by combining rigid building materials with strategically designed grid patterns. The resulting composite object exhibits both the strength of the rigid material and the flexibility of the grid structure, expanding application areas without restricting material choices
2Strength
If objects are manufactured as massive objects from building material, then structural strength is improved, but desired mechanical properties like elasticity cannot be achieved
Solution Approach 1:
The patent segments the object's volume into solid material regions and grid structure regions. This segmentation allows different parts of the object to have different mechanical properties, enabling both strength and elasticity to coexist within the same object
Solution Approach 2:
The patent applies local quality by varying the grid structure characteristics (cell size, shape, wall thickness) in different regions of the object. This allows specific areas to exhibit desired mechanical properties like elasticity while maintaining overall structural strength
3Weight of moving object
If grid structures are used to reduce weight, then weight is improved, but manufacturing complexity increases
Solution Approach 1:
The patent makes the grid structure generation process universal by using automated software that can generate appropriate grid patterns for any object geometry and desired mechanical properties. This reduces manufacturing complexity by providing a one-size-fits-all approach to grid structure creation
Solution Approach 2:
The patent implements self-service through automated algorithms that automatically determine optimal grid structure parameters based on object geometry and desired properties. This eliminates the need for manual design and optimization, reducing manufacturing complexity while maintaining weight benefits
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
Enables the production of objects with varied mechanical characteristics, including flexibility and rigidity, using a single material, expanding the range of possible material properties and enabling the creation of objects with new property combinations.
Implementation Method 1
a laser 6 is provided which generates a laser beam 7 focussed on the working plane 5
Implementation Method 2
the powdery material in the working plane 5, corresponding to a respective object in the respective layers, is solidified by impact of the laser beam 7
Data Source
Figure 1
Figure 2a~4b
Figure 5~6
AI summary
Method of manufacturing a three-dimensional object of a building material by an additive layer-wise building method, wherein based on material parameters of the building material and predetermined characteristics of the object to be manufactured, an internal structure of the object having a grid structure (1) calculated, and the three-dimensional object is manufactured with this internal structure (1) by the additive layer-wise building method, so that it comprises the predetermined characteristics.