Open-Cell Internal Structure Generation for Additive Manufacturing

The infill structure is segmented into a hierarchical system comprising primary infill patterns (grid, triangular, hexagonal) and secondary reinforcement structures (cross-hatching, concentric circles, radial patterns). This segmentation allows each layer to provide specific structural functions, with the primary infill providing base strength and secondary patterns adding targeted reinforcement, thereby achieving high structural strength through organized complexity rather than random densification.

The patent transitions from traditional two-dimensional infill patterns to three-dimensional multi-layer structures by stacking multiple infill layers with varying patterns and orientations. Each layer is positioned at different heights and angles, creating a volumetric reinforcement network that significantly enhances structural strength while maintaining reasonable complexity through systematic layering rather than chaotic material addition.

Different infill patterns and densities are applied to different regions of the printed object based on local structural requirements. High-strength cross-hatching and concentric patterns are concentrated in load-bearing areas and critical joints, while lighter grid patterns are used in non-critical regions. This localized quality optimization achieves overall structural stability while minimizing total material consumption by avoiding uniform over-engineering throughout the entire object.

Instead of applying dense infill uniformly throughout the entire object, the patent uses partial dense infill only where structurally necessary. Critical load paths and stress concentration zones receive enhanced reinforcement with higher density patterns, while peripheral and low-stress areas use sparser infill. This partial action approach achieves sufficient structural stability without the excessive material consumption that would result from uniform dense infill across the entire object.

The infill generation system dynamically adapts pattern selection and density parameters based on real-time analysis of the object's geometry and expected load conditions. The system automatically identifies critical regions requiring reinforcement and adjusts infill patterns accordingly, transitioning from static uniform infill to dynamic variable infill. This dynamic approach achieves high structural efficiency through context-aware pattern distribution while managing manufacturing complexity through automated algorithmic generation rather than manual design.

The patent systematically varies multiple infill parameters including pattern type (grid, triangular, hexagonal, cross-hatch), infill density (10-100%), layer thickness, and orientation angles across different regions and layers of the object. These parameter changes are coordinated to optimize structural efficiency for specific loading conditions while the slicing software manages the complexity of generating and coordinating these varied parameters throughout the printing process.