Meshed 3D Printed Light Fixture to Reduce Warpage
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Solution Overview
Problem
3D printed lighting fixtures face challenges with warpage and delamination due to stress-induced deformations from material shrinkage during cooling and solidification, leading to mechanical instability and integrity issues.
Innovation Solution
A 3D printed light fixture design incorporating both meshed and solid wall parts, where the sum of the perimeters of meshed wall segments exceeds that of solid wall parts in each layer, mitigating stress accumulation and enhancing mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid wall parts are used in 3D printed fixtures, then mechanical robustness and strength are improved, but stress accumulation and warpage risk increase due to material shrinkage during cooling
Solution Approach 1:
The wall parts of the fixture are segmented into meshed wall parts consisting of multiple wall segments, where material is added in a discontinuous, segmented manner rather than as a solid continuous structure. This segmentation reduces stress accumulation during layer stacking while maintaining mechanical strength through the distributed segment structure.
Solution Approach 2:
Different wall parts of the fixture are assigned different structural qualities: some walls are made solid for high mechanical strength requirements, while other walls are made meshed for reduced stress accumulation. The perimeter ratio criterion (sum of meshed wall perimeters exceeding solid wall perimeters) ensures optimal local quality distribution throughout the fixture.
2Stability of the object's composition
If meshed wall parts are used in 3D printed fixtures, then stress accumulation is reduced, but mechanical strength decreases compared to solid structures
Solution Approach 1:
The fixture merges two previously separate design approaches (solid wall structures and meshed wall structures) into a single hybrid design. By combining solid wall parts and meshed wall parts in the same fixture according to the perimeter ratio criterion, the design achieves both stress reduction benefits of meshed structures and mechanical strength benefits of solid structures.
Solution Approach 2:
The wall structure uses a composite approach combining solid material regions and meshed material regions within the same fixture. This composite structural material distribution allows different regions to perform different functions: solid regions provide strength while meshed regions provide stress relief, creating an optimized composite structural system.
3Strength
If solid wall structures are used, then mechanical robustness is improved, but thermal management capability deteriorates
Solution Approach 1:
Different wall parts are assigned different thermal qualities based on local requirements: meshed wall parts with higher porosity are placed in regions requiring thermal management to facilitate heat dissipation, while solid wall parts are placed in regions prioritizing mechanical strength. This local quality differentiation optimizes both thermal and mechanical performance.
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 design reduces the risk of warpage and delamination, improves mechanical stability, and allows for better thermal management and reduced material costs while maintaining structural integrity.
Implementation Method 1
stresses may be induced between subsequent layers as the molten material starts to cool down and solidify. The stresses have been observed to be closely related to the material shrinking during the cooling and/or solidification process.
Data Source
AI summary
A 3D printed fixture (100) for a luminaire is provided. The 3D printed fixture comprises at least one meshed wall part (110) and at least one solid wall part, wherein the meshed wall part further comprises a plurality of wall segments (112) defining a plurality of apertures (114) extending through the meshed wall part. The solid wall part and the meshed wall part are formed by a plurality of layers (130) stacked on each other in a stacking direction. Each layer forms cross sectional portions (116) of the plurality of wall segments of the meshed wall part and a cross-sectional portion (126) of the solid wall part. For each layer, the sum of the perimeters of the cross-sectional portions of the plurality of wall segments exceeds the perimeter of the cross-sectional portion of the solid wall part.