3D Printed Interior Infill With Transitional Bonding Layers
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Solution Overview
Problem
3D printing of interior infills is slow and prone to inaccuracies, particularly in fused deposition modeling, leading to irregular tactile feeling and uneven compression, and conventional methods fail to provide stability under external forces.
Innovation Solution
A method involving a first and second infill pattern with different general directions and a transitional infill pattern with increased cross-sectional width to enhance bonding and stability, allowing rapid printing with minimal material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If printing speed is increased to reduce manufacturing time, then productivity is improved, but manufacturing precision deteriorates leading to inaccuracies in the printed material
Solution Approach 1:
The patent applies different line widths to different regions of the infill pattern. Transitional lines that connect layers have larger cross-sectional widths than standard infill lines, creating local variations in material distribution that ensure bonding accuracy without sacrificing overall printing speed.
Solution Approach 2:
The patent pre-defines specific patterns for transitional lines with enlarged cross-sections at locations where layer bonding is critical. This preliminary design of bonding zones ensures that when high-speed printing occurs, the essential bonding areas maintain sufficient material volume and accuracy.
2Ease of manufacture
If infill layers are printed with lines extending in a single general direction to simplify the printing process, then ease of manufacture is improved, but stability of the object's composition deteriorates causing collapse under external forces
Solution Approach 1:
The patent segments the infill structure into multiple directional sets of layers. Different layers have lines extending in different general directions (e.g., 0 degrees, 60 degrees, 120 degrees), creating a multi-directional reinforcement pattern that prevents collapse while maintaining manufacturing simplicity through systematic layering.
Solution Approach 2:
The patent creates a composite infill structure by combining multiple sets of layers with different line orientations. This composite arrangement of directional layers provides enhanced mechanical stability and resistance to collapse under external forces compared to single-directional infill.
3Strength
If cross-sectional width of infill lines is increased to improve bonding between layers, then strength is improved, but quantity of substance increases leading to higher material usage
Solution Approach 1:
The patent applies larger cross-sectional widths only to transitional lines that perform bonding functions between layers, while standard infill lines maintain smaller cross-sections. This localized increase in material volume provides necessary bonding strength without proportionally increasing overall material consumption.
Solution Approach 2:
The patent uses excessive material (larger cross-section) only where absolutely necessary for bonding, and partial material (smaller cross-section) in non-critical infill regions. This partial application of excessive material achieves sufficient bonding strength while minimizing total material usage.
Data Source
AI summary
A method of printing an interior infill using a 3D printer includes the steps of: defining a planar first infill pattern of lines having a first cross-sectional width; defining a planar second infill pattern of lines having a second cross-sectional width; defining a planar transitional infill pattern of lines having a third cross-sectional width exceeding the first cross-sectional width and the second cross-sectional width; and printing a first set of layers of the first infill pattern, a transitional set of layers of the transitional infill pattern, and a second set of layers of the second infill pattern such that the transitional set of layers is printed between the first set of layers and the second set of layers. An article has a layered interior infill and a computer system is for designing an interior infill of an article.