3D Printed Elastic Structure with Layered Rigidity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing 3D printed structures are often stiff due to the materials used, making them inflexible and challenging to achieve controlled flexibility and counterforce in specific areas, especially when individualization is required, as traditional flexible layers like PU foam reduce flexibility with increased structural strength and weight, and are costly to mold for personal customization.
Innovation Solution
A 3D printed structure comprising a primary structural layer and multiple flexible layers with varying rigidity, allowing the structure to deform under compressive force while maintaining shape, and return to its original form, with the ability to predictably deflect in specific areas by adjusting the ratio of flexible to structural layers, using materials like silicone with controlled thickness and Shore A hardness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional flexible materials like PU foam are used to provide flexibility, then the structure can maintain certain form and flexibility, but the flexibility reduces when structural strength is increased and the weight increases
Solution Approach 1:
The wall is divided into multiple layers with different rigidity values, where each layer contributes differently to the overall structural properties. This segmentation allows the structure to achieve the desired strength without requiring a single heavy material to provide all properties.
Solution Approach 2:
The invention uses a composite structure consisting of multiple layers with different rigidity characteristics. By combining layers of varying rigidity, the structure achieves both strength and flexibility without the weight penalty of using traditionally heavy flexible materials like PU foam.
2Strength
If traditional flexible materials like PU foam are used to provide flexibility, then the structure can maintain certain form and flexibility, but the flexibility reduces when structural strength is increased
Solution Approach 1:
The wall is divided into multiple layers with different rigidity values, where each layer contributes differently to the overall structural properties. This segmentation allows the structure to achieve the desired strength without requiring a single heavy material to provide all properties.
Solution Approach 2:
Different portions of the wall structure have different rigidity characteristics through the use of layers with varying rigidity values. This allows specific areas to be more flexible or stronger based on local requirements, optimizing both overall strength and localized flexibility.
3Adaptability or versatility
If individualization of flexible structures is required, then personalized contours and flexibility can be achieved, but expensive individual molds are required for each user
Solution Approach 1:
The invention enables individualization by varying the rigidity parameter of different layers through the 3D printing process. By changing material composition or layer density during printing, personalized contours and flexibility characteristics can be achieved without requiring expensive individual molds for each user.
Solution Approach 2:
The invention replaces the traditional mechanical molding system (which requires expensive physical molds) with a 3D printing system that uses digital models and variable material deposition. This substitution eliminates the need for costly individual molds while maintaining the ability to produce personalized structures.
4Stability of the object's composition
If 3D printed structures use stiff materials to maintain structural integrity, then the structure maintains its shape during application of external force, but the structure becomes relatively inflexible
Solution Approach 1:
The wall is divided into multiple layers with different rigidity values, where each layer contributes differently to the overall structural properties. This segmentation allows the structure to achieve the desired strength without requiring a single heavy material to provide all properties.
Solution Approach 2:
The invention uses a composite structure consisting of multiple layers with different rigidity characteristics. By combining layers of varying rigidity, the structure achieves both strength and flexibility without the weight penalty of using traditionally heavy flexible materials like PU foam.
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
The structure achieves controlled flexibility and shock absorption, maintaining counterforce while allowing predictable deformation, enabling customizable and efficient use in applications like shoe midsoles and other personal items without the need for expensive individual molds.
Implementation Method 1
a 3D printed structure of an elastic material, the 3D printed structure comprising: at least a first wall configured to deform when a force is applied to the wall in a direction of a first axis and configured to return to its original form when the applied force is released
Data Source
AI summary
A 3D printed structure of an elastic material may be provided. In one implementation, the 3D printed structure may include at least a first wall having a plurality of layers extending along a first axis. The first wall may include at least a primary structural layer, a first flexible layer, and a second flexible layer. The primary structural layer may have a first rigidity and at least one of the first flexible layer or the second flexible layer may have a second rigidity, the first rigidity being greater than the second rigidity.