3D Printing Porous Infill Along Curved Circumferences
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Solution Overview
Problem
Existing 3D printing methods for creating porous structures, particularly for medical implants, result in loose ends and rough surfaces due to orthogonal repetition of unit cells, leading to inaccuracies and potential harm to tissue during insertion.
Innovation Solution
Adapting the porous infill structure to match the circumference of the object by changing the pattern to be non-orthogonal, using methods such as altering the infill pattern, applying non-linear coordinate transformations, and adding tracks with low density to support the ends, ensuring they are supported by underlying structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If orthogonal repetition of unit cells is used for infill structure, then manufacturing process is simple, but surface smoothness deteriorates and loose ends are created
Solution Approach 1:
The patent applies different infill patterns to different regions of the object. The peripheral regions use a first infill pattern that follows the circumference to ensure smooth surfaces and support loose ends, while the central region uses a second infill pattern for efficient material distribution. This local differentiation resolves the contradiction by optimizing each region according to its specific requirements.
Solution Approach 2:
The patent dynamically adjusts the infill pattern based on the radial position from the center of the object. By varying the infill pattern selection based on distance from the center, the system automatically creates appropriate structures in different zones, ensuring smooth peripheral surfaces while maintaining manufacturing efficiency in the center.
2Ease of operation
If orthogonal grid infill is used, then printing process is straightforward, but accuracy of loose end pieces deteriorates
Solution Approach 1:
The patent applies a specialized first infill pattern specifically to peripheral regions where loose ends occur, while maintaining a standard second infill pattern for the central region. This localized approach ensures high accuracy at the periphery without complicating the overall printing process.
Solution Approach 2:
The system pre-calculates and prepares different infill patterns for different regions before printing begins. By preparing the appropriate infill pattern in advance for peripheral versus central regions, the system ensures accurate printing of loose end pieces while keeping the overall process straightforward.
3Quantity of substance
If standard infill pattern is applied to curved surfaces, then material usage is efficient, but surface roughness increases
Solution Approach 1:
The patent applies a first infill pattern specifically to curved peripheral regions to maintain surface smoothness, while using a second infill pattern for flat or less critical central regions. This ensures efficient material usage in the center while preventing surface roughness at the curved periphery.
Data Source
AI summary
The disclosure relates to a method for three dimensional (3D) printing an object, the method comprising the steps of:—providing a print job, the print job comprising a representation of the object,—dividing the representation of the object in one or more bodies;—for each body, define settings for printing the respective body, wherein settings for at least one body include filling the body with a porous infill structure;—slicing the representation of the object in a number of slices,—the step of slicing comprising, for the body to be filled with the porous infill structure:—defining for every slice an infill area that is to be filled with the porous infill structure;—defining a circumference of the infill area;—adapting the porous infill structure to the circumference; and—filling the infill area with the adapted infill structure.