Custom In-Fill Pattern for Additive Manufacturing Core Structure
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Solution Overview
Problem
Existing 3D printing methods are limited by using standard, fixed geometries for in-fill patterns that are oriented normal to the build plane, which fail to provide customized support structures that meet the specific structural requirements of parts, leading to inefficiencies in material usage and structural integrity.
Innovation Solution
An additive manufacturing method that involves determining a custom in-fill pattern with preferred orientations and geometries for the core structure of a part, slicing the computational model into individual segments, and building layers sequentially using a 3D printer with multiple material sources to deposit materials according to the custom pattern, allowing for varied density and orientation of support members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard in-fill patterns oriented normal to the build plane are used, then the manufacturing process is simple and fast, but the structural support does not meet specific structural requirements of parts
Solution Approach 1:
The patent applies local quality by customizing in-fill patterns for specific regions of the part based on local structural requirements. Different sections of the part can have different in-fill geometries, densities, and orientations tailored to their specific load-bearing needs, rather than using a uniform pattern throughout the entire part.
Solution Approach 2:
The patent implements dynamics by making in-fill patterns adaptable and variable throughout the part structure. The in-fill geometry, density, and orientation can dynamically change from one region to another based on structural requirements, allowing the structure to optimize material distribution according to local stress and load conditions.
2Strength
If custom in-fill patterns with varied density and orientation are implemented, then structural support is optimized for part performance, but material usage and manufacturing complexity increase
Solution Approach 1:
The patent applies parameter changes by varying multiple in-fill parameters including density, geometry, and orientation throughout different regions of the part. These parameter variations are strategically implemented to optimize structural support where needed while reducing material usage in non-critical areas, achieving a balance between strength and material efficiency.
Solution Approach 2:
The patent uses local quality to apply higher material density and more complex in-fill patterns only in regions requiring enhanced structural support, while using simpler, less dense patterns in non-critical regions. This localized approach optimizes material distribution to match actual structural needs.
3Weight of moving object
If in-fill patterns are oriented relative to the part's surface rather than the build plane, then weight is reduced and strength is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies dimensionality change by transitioning from the conventional build-plane-aligned in-fill orientation to a part-surface-relative orientation system. This allows in-fill patterns to be defined in the part's local coordinate system rather than the global build coordinate system, enabling weight optimization through surface-normal alignment while managing manufacturing complexity through computational methods.
Solution Approach 2:
The patent implements parameter changes by modifying the orientation parameter of in-fill patterns from being fixed relative to the build plane to being variable relative to the part's surface geometry. This enables adaptive orientation that follows the part's shape and functional requirements, reducing weight while maintaining manufacturability through software-based control.
4Reliability
If varied density and geometry of support members are used, then structural integrity of complex shapes is enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies local quality by implementing varied density and geometry of support members in specific regions based on local structural requirements. Critical areas receive higher density and more complex geometries, while non-critical areas use simpler patterns, thereby enhancing overall structural integrity without uniformly increasing manufacturing precision requirements across the entire part.
Solution Approach 2:
The patent implements dynamics by making the in-fill pattern properties (density, geometry) variable and adaptive throughout the part structure. This allows the system to dynamically adjust material distribution and pattern complexity to match local structural demands, enhancing reliability while managing manufacturing precision through software-controlled variability rather than uniform high precision requirements.
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 parts with optimized structural support that matches the intended use, reducing weight and improving strength by orienting in-fill patterns relative to the part's surface, rather than the build plane, and allows for varied density and geometry of support members, enhancing the structural integrity of complex shapes like curved and winglet parts.
Implementation Method 1
an additive manufacturing method for improved core structure is provided. The method includes providing a computational model of a part having a core portion, determining a custom in-fill pattern for supporting the core portion, slicing the computational model into a predetermined number of slices having a predetermined orientation based on the computational model and the custom in-fill pattern
Data Source
AI summary
An additive manufacturing method for improved core structure includes splitting a computational model into sequentially queued individual model segments based on a predetermined number of slices with a predetermined orientation, and building a part in layers applied sequentially to form a final part having a core portion supported with a custom in-fill pattern. An additive manufacturing system for providing an improved core structure supported by a custom in-fill pattern includes a controller having instructions for individual model segments based on slices of a solid model, and a 3D printer for sequentially printing individual model segments in adjacent layers. A 3D-printed part includes a first exterior surface separated by a gap from a second exterior surface, and an internal core structure within the gap for mechanically connecting the first exterior surface to the second exterior surface. The internal core structure includes a custom in-fill pattern of support members.