Multi-Part 3D Printing Filament for Self-Supporting Structures
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Solution Overview
Problem
Current fused filament fabrication machines are limited by the complexity of parts they can manufacture due to the sequential stacking of two-dimensional layers, which restricts the formation of self-supporting structures.
Innovation Solution
The development of multi-part filaments comprising a first and second body part with differing rigidity characteristics, allowing for the creation of self-supporting structures without lateral support during additive manufacturing, achieved through the use of curable polymer materials with distinct curing properties and optional inclusion of fibers or voids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional fused filament fabrication uses sequential stacking of two-dimensional layers, then the manufacturing process is simple and reliable, but the complexity of parts that can be manufactured is limited and self-supporting structures cannot be formed
Solution Approach 1:
The filament is divided into multiple distinct body parts (first body part, second body part, etc.) with different materials and rigidity characteristics. This segmentation allows each part to serve different functions - some parts provide structural support while others form the final part geometry, enabling complex self-supporting structures to be manufactured.
Solution Approach 2:
Different body parts of the filament are assigned different local qualities, specifically different rigidity characteristics. The first body part has different rigidity than the second body part, allowing specific regions of the filament to provide support where needed while other regions form the desired part geometry, thus enabling self-supporting structure formation.
2Adaptability or versatility
If multi-part filaments with differing rigidity are used to create self-supporting structures, then complex three-dimensional parts can be manufactured without lateral support, but the filament structure becomes more complex
Solution Approach 1:
The filament is segmented into multiple body parts with distinct rigidity characteristics, allowing specific segments to provide self-support during dispensing while other segments form the final part geometry. This enables manufacturing of complex three-dimensional structures without requiring lateral support substrates.
Solution Approach 2:
The invention transitions from two-dimensional layer stacking to three-dimensional dispensing by using multi-part filaments with different rigidity. The varying rigidity along the filament's length allows it to maintain complex three-dimensional shapes during dispensing, enabling true 3D structure formation rather than sequential layer assembly.
3Ease of manufacture
If traditional filaments are used without substrate support, then the manufacturing process is simpler, but the filament cannot maintain its shape and structure during dispensing
Solution Approach 1:
Different body parts of the filament are assigned different local rigidity qualities. The body parts with higher rigidity provide structural support and maintain the filament's shape during dispensing, while body parts with lower rigidity allow the filament to be formed into the desired part geometry. This differential rigidity enables the filament to maintain structural integrity without external substrate support.
Solution Approach 2:
The filament is constructed as a composite structure with multiple body parts made from different materials or with different rigidity characteristics. This composite structure allows the filament to simultaneously provide its own structural support while being formable into the desired final shape, eliminating the need for external substrate support during manufacturing.
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 the fabrication of complex, self-supporting three-dimensional parts by ensuring the multi-part filament maintains its shape and structure during dispensing, overcoming the limitations of traditional layering methods.
Implementation Method 1
achieved through the use of curable polymer materials with distinct curing properties
Data Source
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AI summary
Multi-part filaments 10 for additive manufacturing comprise an elongate filament body 12. The elongate filament body 12 comprises a first body part 14 extending longitudinally along the elongate filament body 12, and a second body part 16 extending longitudinally along the elongate filament body 12. The first body part 14 comprises a first material 18, and the second body part 16 comprises a second material 20. One of the first body part 14 and the second body part 16 is more rigid than the other of the first body part 14 and the second body part 16 and is sufficiently rigid to print self-supporting structures from the multi-part filament 10.