3D Bio-Mimicked Closed-Cell Lattices Without Print Supports
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Solution Overview
Problem
The challenge lies in the difficulty of additive manufacturing of closed cell lattice structures due to the need for support structures during fabrication, which limits their production efficiency and material usage compared to open cell structures.
Innovation Solution
The development of a support-less additive manufacturing process using material extrusion for bio-mimicked three-dimensional laminated structures, specifically shell-shaped structures inspired by sea urchins, which allows for the creation of closed cell lattice structures without the need for additional support, enabling the production of parts with varying volume fractions and unit cell sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If closed cell lattice structures are manufactured using traditional additive manufacturing processes, then the structures can be fabricated, but support structures are required during fabrication which increases device complexity and reduces productivity
Solution Approach 1:
The patent segments the lattice structure into self-supporting unit cells with specific geometric configurations (such as tetrahedral and octahedral arrangements) that can be fabricated without external support structures. Each unit cell is designed to be self-sufficient during the printing process.
Solution Approach 2:
The patent employs curved and rounded geometric features in the lattice structure design, such as spherical nodes and curved struts, which inherently provide self-support during material extrusion printing. These curved geometries distribute material deposition more effectively and prevent sagging without requiring additional support structures.
2Ease of manufacture
If support structures are used during additive manufacturing of closed cell lattice structures, then fabrication is enabled, but material consumption increases and post-processing is required
Solution Approach 1:
The patent extracts and eliminates the support structure requirement from the manufacturing process by redesigning the lattice geometry itself to be self-supporting. This removes the need for additional material that would otherwise be consumed in creating and subsequently removing support structures.
Solution Approach 2:
The lattice structure is designed to be self-supporting during fabrication, where the geometry of the unit cells themselves provides the necessary support during material deposition. The structure serves its own support function without requiring external support elements.
3Productivity
If traditional lattice structures are manufactured, then production can proceed, but energy consumption increases due to support structure fabrication and removal
Solution Approach 1:
The patent removes the energy-intensive support structure fabrication and removal steps from the manufacturing process by designing self-supporting lattice geometries. This directly reduces the total energy consumption while maintaining production capability.
Solution Approach 2:
The self-supporting lattice design enables continuous material deposition without interruption for support structure removal. The printing process can proceed continuously layer by layer without pausing for post-processing, improving productivity and reducing energy consumption.
4Ease of manufacture
If closed cell lattice structures are fabricated with support structures, then manufacturing is possible, but production time increases due to post-processing requirements
Solution Approach 1:
The patent extracts the time-consuming support structure removal step from the manufacturing process by designing lattices that are self-supporting. This eliminates the post-processing time while maintaining manufacturing feasibility.
Solution Approach 2:
The self-supporting geometry allows the additive manufacturing process to proceed continuously without interruption for support removal. The entire fabrication process from start to finish occurs in a single continuous operation, maximizing productivity.
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 efficient fabrication of closed cell lattice structures with improved load-bearing capacity, reduced material and energy consumption, and eliminates the need for post-processing to remove support structures, resulting in higher stiffness and fail-safe designs compared to open cell structures.
Implementation Method 1
additive manufacturing process, especially closed cell bio-mimicked three-dimensional laminated structure with material extrusion process
Data Source
AI summary
A invention disclosed a bio-mimicked three-dimensional laminated structure at least comprising a flexible lattice structure, which is characterized in that the flexible lattice structure comprises a plurality of particle units are uniformly disposed and evenly distributed in the X-axis, the Y-axis, and the Z-axis direction and evenly distributed as a lattice matrix of an array grid in an identical plane; wherein each of the particle units is an opened hollow shell or a close shell. The design eliminates the need for support structures and the subsequent post-processing required to remove them. A shell-shaped close cell bio-mimicked three-dimensional laminated structure bio-mimicking a sea urchin shape was introduced for the load-bearing structure application.