Corrugated 3D Printing Layers for Shear-Resistant Structures
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Solution Overview
Problem
Current 3D printing technologies rely on planar layer construction, which leads to inherent structural weaknesses due to susceptibility to shear forces, limiting the strength and durability of 3D printed objects.
Innovation Solution
The method involves forming corrugated layers using a 3D printer, where the layers can vary in height along their length, providing a cross-sectional area that is either constant or varying, and are taller than conventional planar layers, along with the use of transition layers to integrate these corrugated layers into the printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If planar layer construction is used in 3D printing, then the printing process is simple and straightforward, but the structural strength and resistance to shear forces deteriorate
Solution Approach 1:
The patent applies curvature by forming corrugated layers with wave-like profiles instead of flat planar layers. The corrugation pattern introduces vertical undulations that create arch-like structures, naturally resisting shear forces through geometric configuration while maintaining the additive manufacturing process
Solution Approach 2:
The invention transitions from two-dimensional planar layers to three-dimensional corrugated structures by adding vertical height variation. The corrugated layers extend in the build direction with controlled height profiles, creating a multi-layered 3D architecture that enhances structural performance without compromising manufacturing simplicity
2Strength
If corrugated layers with varying height are formed, then structural strength and shear force resistance improve, but the manufacturing complexity increases
Solution Approach 1:
The patent controls the complexity by systematically varying parameters such as corrugation amplitude, wavelength, and height profile along the layer length. These parameter changes are implemented through programmed toolpath generation in the 3D printing process, allowing complex geometries to be created through algorithmic control rather than mechanical complexity
Solution Approach 2:
The invention introduces transition layers as intermediary structures between planar and fully corrugated regions. These transition layers gradually introduce corrugation features, allowing smooth geometric transitions that reduce manufacturing complexity while maintaining structural integrity and avoiding abrupt changes that would require complex tooling
Data Source
AI summary
In some aspects, described herein are methods of additive manufacturing in which one or more corrugated layers are incorporated into the three-dimensional (3D) object. Also provided herein are 3D objects that can include one or more corrugated layers.