3D Printed Internal Bridge With Anchor Layer
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Solution Overview
Problem
Existing 3D printing technologies face limitations in achieving maximum bridging distances without supports, typically restricted to about 1.75 mm, which hinders the creation of wider internal channels in 3D parts.
Innovation Solution
A method and system for printing internal bridges in 3D objects by depositing drops of printing material to form supported and unsupported stepouts, along with anchor layers, at specific drop spacings and angles, allowing for increased bridging distances without external supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If conventional 3D printing methods are used, then the maximum bridging distance is limited to about 1.75 mm, but this restriction prevents the creation of wider internal channels in 3D parts
Solution Approach 1:
The bridge is divided into multiple segments: supported stepouts, unsupported stepouts, and anchor layers. Each segment serves a specific function in extending the bridge beyond the conventional 1.75 mm limit while maintaining structural integrity through alternating support and unsupported sections
Solution Approach 2:
The invention introduces a vertical dimension by creating stepouts that extend in the Z-direction while maintaining X-Y plane bridging. The anchor layers provide vertical support structures that enable horizontal bridging distances exceeding the conventional limit by utilizing three-dimensional spatial arrangement
2Length of stationary object
If supports are used to increase bridging distance, then wider channels can be created, but the complexity of the printing process and part structure increases
Solution Approach 1:
The anchor layers are formed using the same printing material and process as the bridge structure itself, merging the support function into the bridge construction. This eliminates the need for separate support materials or complex support structures, as the anchor layers are integral portions of the bridge
Solution Approach 2:
The bridge structure provides its own support through the alternating pattern of supported and unsupported stepouts. The anchor layers self-form as part of the printing process, requiring no external support structures or additional manufacturing steps beyond the standard 3D printing sequence
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 enables the creation of internal bridges with extended lengths, up to 25 mm, by optimizing drop spacings and layer formations, thereby expanding the design possibilities for 3D printed parts with internal channels.
Implementation Method 1
A method of printing an internal bridge in a three-dimensional object includes depositing a plurality of drops of a printing material to form a bridge
Data Source
AI summary
A method of printing an internal bridge in a three-dimensional object includes depositing a plurality of drops of a printing material in a first direction to form a supported stepout onto an edge of a bridging layer, depositing a plurality of drops of the printing material to form an anchor layer adjacent to and in contact with a supported stepout, and depositing a plurality of drops of the printing material to form an unsupported stepout adjacent to an in contact with the supported stepout. A printing system for three-dimensional objects is also described, which is configured to perform the method of printing an internal bridge in a three-dimensional object.