Pseudo-Gyroid Modeled Objects with Variable Layer Spacing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing methods produce objects with complex shapes that are either too stiff or prone to delamination, making them unsuitable for applications requiring isotropic deformability and natural softness, such as cushioning materials for the human body.
Innovation Solution
The method involves selecting tool paths for forming single-layer structures with varying interlayer spacings based on the shape change between upper and lower layers, using a pseudo-gyroid structure with folded resin ends to prevent delamination and maintain isotropic deformability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a complex-shaped structure such as a gyroid structure is used to achieve isotropic deformability, then the deformability against loading from different directions is improved, but the manufacturing precision and time are worsened
Solution Approach 1:
The complex gyroid structure is segmented into multiple single-layer structures, each with a simpler shape. These single-layer structures are then laminated together to form the complete complex object, allowing each layer to be manufactured with high precision while collectively achieving the desired isotropic deformability
Solution Approach 2:
The invention uses variable interlayer spacing where the spacing between layers is adjusted based on the local curvature and shape changes of the gyroid structure. This dynamic adjustment of layer spacing allows the complex 3D shape to be built up layer by layer with appropriate precision at each stage
2Strength
If a peripheral line portion is added to increase the strength of the object, then the strength is improved, but the natural softness is worsened
Solution Approach 1:
Instead of adding a peripheral line portion that uniformly increases stiffness, the invention modifies the local quality of individual single-layer structures by incorporating folded portions. These folded portions are strategically placed to provide strength enhancement only where needed, while maintaining the natural softness of the overall object surface
Solution Approach 2:
The folded portions are nested within the single-layer structures themselves, with the resin folding back on itself to create reinforcing features that are integrated into the layer geometry rather than added as separate peripheral elements
3Manufacturing precision
If the interlayer spacing is reduced to improve manufacturing precision, then the manufacturing precision is improved, but the manufacturing time is worsened
Solution Approach 1:
The invention changes the parameter of interlayer spacing dynamically across different regions of the object. In areas requiring high precision, the spacing is reduced; in areas where the shape changes gradually, the spacing can be increased, thereby optimizing both precision and manufacturing time across the entire structure
Data Source
AI summary
The present invention provides a modeled object manufacturable with high precision in a short amount of time that may have a complex-shaped base structure. According to the present invention, the object is manufactured from modeling data prepared by selecting part of tool paths, from source data, for forming respective single-layer structures obtained by slicing a base structure at predetermined modeling pitches, wherein the selecting is performed in such a way that the larger a change in shape between tool paths of upper and lower layers is in the source data, the shorter an interlayer spacing in the source data is made.