3D Printing Infill Path Sequencing for Warping Reduction
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Solution Overview
Problem
Current 3D printing technologies often require the creation of solid objects, which can be material and time intensive, and do not efficiently manage internal forces during the printing process, leading to potential warping and material contraction issues.
Innovation Solution
A three-dimensional modelling system analyzes a 3D model to determine where internal supports are needed, allowing for the creation of hollow shells and optimizing print paths to reduce material usage and internal forces by skipping infill structures where angles are sufficient and localizing contractive forces through open cell lattice structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid objects are created using 3D printing, then structural strength is improved, but material consumption and print time increase
Solution Approach 1:
The patent segments the internal structure into discrete infill patterns (e.g., grids, honeycombs, lattices) rather than using solid material. This segmentation maintains structural strength while significantly reducing material consumption by creating a framework that provides support only where needed.
Solution Approach 2:
The patent applies local quality by varying infill density and pattern based on local structural requirements. Critical areas receive higher infill density for strength, while non-critical areas use lower density to reduce material consumption and print time.
2Strength
If solid objects are created using 3D printing, then structural integrity is improved, but print time increases
Solution Approach 1:
By segmenting the internal structure into infill patterns, the patent reduces the total volume of material that needs to be deposited, directly reducing print time while maintaining structural integrity through the strategic placement of support structures.
Solution Approach 2:
The patent applies partial action by providing infill support only in regions where it is structurally necessary, rather than filling the entire object. This selective approach reduces print time while maintaining adequate structural integrity.
3Productivity
If continuous material deposition is performed, then printing efficiency is improved, but warping and contraction issues increase
Solution Approach 1:
The patent segments the deposition process into discrete infill regions and patterns, allowing for better thermal management. The segmented structure creates natural break points that reduce cumulative warping and contraction effects compared to continuous deposition.
Solution Approach 2:
The patent uses porous infill structures that allow for thermal expansion and contraction without generating excessive internal stresses. The void spaces in the infill pattern provide relief for material shrinkage, reducing warping while maintaining printing efficiency.
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 reduces material consumption, print time, and minimizes warping by creating internal supports only where necessary and using open cell lattices to manage contractive forces, resulting in a more efficient and stable printing process.
Implementation Method 1
a three-dimensional extrusion printer that includes a tool-head that will create at least a portion of the object
Implementation Method 2
sequential material cooling... allow a recently deposited fill line to cool before deposition of a neighboring fill line
Data Source
AI summary
Methods, systems, and apparatus, including computer programs encoded on computer storage media, for working with three-dimensional object models for printing. One of the methods includes determining a plurality of infill structures in a slice of an object; and determining a path for the tool-head to create the plurality of infill structures including: determining a first portion of the path for deposition of a first infill structure during a first time period; determining a second portion of the path for deposition of one or more second infill structures that are not adjacent to the first infill structure during a second time period; and determining a third portion of the path for deposition of a third infill structure that is adjacent to the first infill structure, wherein the second time period is determined to allow the first infill structure to cool before deposition of the third infill structure.