Multiscale Lattice Alignment for 3D Printed Structural Integrity
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Solution Overview
Problem
Existing 3D printing technologies face challenges in maintaining structural integrity when using variable density lattices with different sizes within the same object, leading to weak interfaces between lattice structures, which can cause the object to fall apart without a shell.
Innovation Solution
A system for generating multiscale density threshold matrices that align finer scaled lattices with coarser scaled lattices, ensuring that struts of one lattice structure directly contact struts of another to maintain structural integrity and strength, with scale changes occurring at the border of the fundamental rectangular period.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If variable density lattices with different sizes are used within the same object, then the object can achieve weight reduction and thermal management benefits, but the interface between lattice structures becomes weak causing the object to fall apart
Solution Approach 1:
The patent applies local quality by using different lattice scales in different regions of the object. Finer scaled lattices are used in regions requiring higher strength while coarser scaled lattices are used in regions where weight reduction is prioritized. The density threshold matrix dynamically adjusts the lattice scale at each pixel location, allowing the structure to optimize its properties locally rather than using a uniform lattice throughout.
Solution Approach 2:
The patent changes the scale parameter of the lattice structure dynamically across different regions. By modifying the lattice scaling factor based on the density threshold matrix, the system transitions between different lattice densities and scales. This parameter change allows the same object to have both lightweight regions and structurally robust regions, resolving the contradiction between weight reduction and interface strength.
2Adaptability or versatility
If lattice structures of different sizes are combined, then the object can accommodate both tight and spacious interior spaces effectively, but the structural integrity is compromised due to weak interfaces
Solution Approach 1:
The patent implements local quality by matching lattice scales to the spatial requirements of different regions. In tight interior spaces, finer scaled lattices provide better structural support and density control. In spacious interior spaces, coarser scaled lattices are used to reduce material usage while maintaining adequate structural integrity. This localized adaptation ensures both versatility and stability.
Solution Approach 2:
The patent uses density threshold matrices to copy and replicate lattice patterns across different scales. The same base lattice pattern is replicated at multiple scales (e.g., 2x, 4x, 8x) and selectively applied to different regions based on the density threshold matrix. This copying approach maintains structural consistency while allowing for scale variation, thereby preserving structural integrity across heterogeneous regions.
3Strength
If a shell is added to hold the object together, then structural integrity is maintained, but the complexity and material usage increase
Solution Approach 1:
The patent segments the object into multiple regions with different lattice scales based on the density threshold matrix. Instead of adding a shell, the structure is segmented into finer and coarser lattice regions that are directly integrated into the object's interior. This segmentation allows the object to maintain structural integrity through internal heterogeneity rather than external containment, reducing overall complexity.
Solution Approach 2:
The patent changes the lattice scale parameter dynamically across the object to create self-supporting structures. By adjusting the lattice scaling factor in response to the density threshold matrix, the object develops internal structural variations that provide strength without requiring additional shells or external support structures. This parameter-based approach eliminates the need for extra components.
Data Source
Figure 1A~1B
Figure 2
Figure 3A
AI summary
One example includes a three-dimensional (3D) printed object including a first lattice structure and a second lattice structure. The first lattice structure includes a first matrix having a first length, a first width, and a first height. The second lattice structure includes a second matrix having a second length, a second width, and a second height. The second length times two is a factor of the first length, the second width times two is a factor of the first width, and the second height times two is a factor of the first height.