3D Printed Side Openings with Seam-Free Turn Paths
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Solution Overview
Problem
Current 3D printing methods using fused deposition modeling struggle to create well-defined openings in 3D printed items without increasing wall thickness or resulting in defects, as the nozzle tends to stop at the opening edge or require thicker walls to maintain structural integrity.
Innovation Solution
A method involving layer-wise deposition of 3D printable material where openings are defined by interruptions in the layers, using oppositely arranged turns that connect layer parts, allowing for well-defined openings with reduced material usage and no seams, by adjusting the length and angle of the turns and tool path to minimize material deposition where necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the nozzle stops at the opening edge during 3D printing, then the printing process is simple, but the opening becomes poorly defined
Solution Approach 1:
The patent applies preliminary action by creating support structures (bridges) before the opening is printed. These bridges are deposited in advance to provide a foundation that enables the nozzle to maintain continuous material flow while forming precise opening edges, thereby achieving both manufacturing simplicity and opening precision.
Solution Approach 2:
The patent uses bridges as intermediary structures that mediate between the nozzle and the opening edge. These temporary support structures allow the nozzle to deposit material continuously while maintaining precise control over the opening geometry, resolving the contradiction between simple printing and precise opening definition.
2Strength
If thicker walls are used to maintain structural integrity at openings, then structural strength is improved, but material usage increases and wall thickness is not reduced
Solution Approach 1:
The patent applies local quality by providing enhanced structural support (bridges) only at specific locations where openings are present, rather than uniformly thickening all walls. This localized reinforcement maintains structural integrity at critical opening areas while minimizing overall material usage throughout the printed object.
Solution Approach 2:
The patent changes the structural parameters locally by introducing bridges with specific geometric parameters (length, thickness, positioning) that are optimized for opening support. This allows the structure to achieve necessary strength at openings without increasing wall thickness elsewhere, thereby reducing total material consumption.
3Adaptability or versatility
If openings are created in 3D printed walls, then functional features are added, but the nozzle stopping at opening edges creates defects
Solution Approach 1:
The patent uses preliminary action by depositing bridge structures before creating openings. These pre-deposited bridges provide a stable foundation that allows the nozzle to continue material deposition without stopping at opening edges, thereby eliminating defects while maintaining the functional opening features.
Solution Approach 2:
The bridges act as intermediary structures that enable the nozzle to maintain continuous operation while forming openings. By providing this intermediate support, the system achieves both functional versatility (openings) and reliability (defect-free printing through continuous material flow).
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 creation of 3D items with well-defined openings and reduced material usage, maintaining structural integrity while avoiding the need for thicker walls or seams, suitable for various applications including lighting solutions.
Implementation Method 1
a 3D printing stage comprising layer-wise depositing an extrudate comprising 3D printable material, to provide the 3D item comprising 3D printed material
Data Source
AI summary
A method for producing a 3D item (1) by means of fused deposition modelling, the method comprising a 3D printing stage comprising layer-wise depositing an extrudate (321) comprising 3D printable material (201), to provide the 3D item (1) comprising 3D printed material (202), wherein the 3D item (1) comprises a plurality of layers (322) of 3D printed material (202), and an opening (405) in the 3D printed material (202), the opening (405) having an opening edge (410) that is at least partly defined by one or more interruptions (1410) in a subset (1322) of one or more layers (322) of the plurality of layers (322), wherein the method comprises providing each interruption (1410) by 3D printing a layer (322) of the subset (1322) with oppositely arranged turns (415), wherein each turn (415) connects a first layer part (3221) and a second layer part (3222), the first layer part (3221) and the second layer part (3222) forming legs of a U-turn (435), wherein, for each turn (415), the first layer part (3221) has a first length (LI) and the second layer part (3222) has a second length (L2), the second length (L2) being shorter than the first length (LI) such that over only part of the layer (322) the first layer part (3221) and the second layer part (3222) are configured adjacent, and wherein each turn (415) has a path length (Lr) with a radius of curvature (r1), and wherein each path length (Lr) is selected from the range of 0.9*7c*r1<Lr≤7r*r1.