Modular 3D-Printed Support Block Assembly for Customizable Stiffness
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pillows and support structures are limited to single specifications, failing to accommodate diverse user needs and requiring large machines for 3D printing, leading to high production costs and internal defects.
Innovation Solution
A modular support element assembly composed of standard blocks with varying elastic constants and heights, manufactured by 3D printing, allowing for customizable connection and quick adjustment through jointing structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pillows are manufactured as integral structures by 3D printing, then customization of structure density and strut dimensions is achieved, but production cost increases and internal defects become harder to address
Solution Approach 1:
The pillow is divided into multiple standard blocks that can be manufactured separately and then assembled together. Each standard block can be independently produced using 3D printing with controlled parameters, allowing customization without requiring the entire pillow to be printed as one piece. This segmentation reduces production cost and complexity while maintaining adaptability.
Solution Approach 2:
Multiple standard blocks with different structural properties (density, strut dimensions) are designed to be universally compatible through standardized jointing structures. These universal blocks can be mixed and matched to create various pillow configurations, achieving customization goals while using a limited set of manufacturable components.
2Adaptability or versatility
If pillows are manufactured as integral structures, then heterogeneous structure is achieved, but ease of maintenance and cleaning becomes difficult
Solution Approach 1:
The pillow is segmented into multiple removable standard blocks connected by jointing structures. This segmentation allows individual blocks to be easily detached for cleaning or replacement without affecting the entire pillow structure, solving the maintenance difficulty while preserving heterogeneous structural design.
3Ease of manufacture
If fixed dimensions and materials are used, then manufacturing simplicity is maintained, but user needs for customization are not met
Solution Approach 1:
The pillow design segments the structure into standardized blocks that can be manufactured using simple, repeatable processes. Each block type can be produced independently with fixed parameters, maintaining manufacturing simplicity while the combination of different blocks provides customization capability.
Solution Approach 2:
Different standard blocks are designed with varying parameters such as density, strut dimensions, and height. By changing these parameters across different block types while maintaining standardized connection interfaces, the system achieves customization without complicating the manufacturing process for each individual block.
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
Enables personalized support and comfort adjustments by connecting different standard blocks, reducing production costs and minimizing defects while ensuring lightweight, high precision, and easy maintenance.
Implementation Method 1
The standard blocks are manufactured by 3D printing and have identical lattices
Implementation Method 2
a first elastic constant and a first height, a second standard block having a second elastic constant
Data Source
AI summary
A support element assembly includes at least two types of standard blocks. The standard blocks are connected to each other and selected from the group consisting of a first standard block having a first elastic constant and a first height, a second standard block having a second elastic constant and the first height, a third standard block having the first elastic constant and a second height, and a fourth standard block having the second elastic constant and the second height. The standard blocks are manufactured by 3D printing and have identical lattices, and each standard block has a jointing structure.