Quadrilateral Sparse Infill for 3D Printing

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Solution Overview

Problem

Existing 3D printing technologies face challenges in creating crush-resistant yet lightweight articles with sparse infills, as the structural integrity of infills made from certain materials, such as fiber-reinforced thermoplastic filament, is compromised by cutting and assembly processes, leading to unevenness and structural weakness due to filament bumps.

Innovation Solution

The method involves strategically depositing segments of filament in specific shapes and locations to minimize and eliminate the harmful effects of bumps by carefully distributing overlap and non-overlap areas, enabling the fabrication of quadrilateral and hexagonal infills that maintain structural integrity without weakening the material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If fiber-reinforced thermoplastic filament is cut into segments and assembled to form infill, then the infill can be fabricated with complex geometries, but the structural integrity of the filament is compromised and bumps are created

Engineering Contradiction:

Improveinfill geometry complexityVSAvoidfilament structural integrity

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The filament path is divided into multiple linear segments that are deposited sequentially by the 3D printer. Each segment is carefully planned to minimize overlaps and bumps while maintaining the ability to create complex infill geometries. The segmentation allows the system to adapt to complex shapes without continuously cutting and rejoining filament, preserving structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent acknowledges that bumps will occur at segment intersections but converts this harmful effect into a beneficial one by strategically placing bumps in locations where they do not compromise structural integrity. The system uses mathematical optimization to identify bump locations that minimize overall structural weakness while still enabling complex geometry fabrication.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Strength

If filament segments are deposited with overlaps to ensure continuity, then structural integrity may be maintained, but bumps are created that cause unevenness and weakness

Engineering Contradiction:

Improveinfill structural integrityVSAvoidinfill surface uniformity

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent applies different deposition strategies to different regions of the infill. In critical structural areas, segments are arranged to minimize overlaps and avoid bumps. In non-critical areas, overlaps are acceptable. This local optimization allows the system to maintain high manufacturing precision where needed while still achieving overall structural integrity.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent performs preliminary planning of the filament path before deposition, using mathematical algorithms to optimize segment locations and minimize bumps. By pre-calculating the optimal path that avoids excessive overlaps, the system can maintain both structural integrity and surface uniformity without requiring real-time adjustments during deposition.

Inventive Principle:

Principle #10Preliminary action

3Strength

If filament is continuously deposited without cutting, then structural integrity is maintained, but complex infill geometries cannot be achieved

Engineering Contradiction:

Improvefilament continuityVSAvoidinfill geometry complexity

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent implements a dynamic filament deposition system that can switch between continuous deposition and segmented deposition based on the local geometric requirements. In regions where continuous deposition can achieve the desired geometry, the system maintains filament continuity. In regions requiring sharp corners or complex patterns, the system strategically introduces segments while minimizing disruptions to structural integrity.

Inventive Principle:

Principle #15Dynamics

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

This approach results in articles with improved structural strength and reduced weight, achieving a balance between crush resistance and lightness by optimizing the distribution of filament segments in additive manufacturing.

Implementation Method 1

It is well-known in the prior art how to make an infill using ABS with fused-deposition modeling ('FDM').

Methodology Applied

Scientific EffectFused-deposition modeling: 3D Printing

Implementation Method 2

the mere act of cutting the filament irreparably weakens the material, and fusing the various segments does not fix the problem.

Methodology Applied

Scientific EffectThermal fusion: Heating

Data Source

PatentUS10611079B2Quadrilateral sparse infill made of linear segments of filament

Publication Date: 2020.04.07 STRATASYS INC

AI summary

An article of manufacture is disclosed that comprises an infill made from linear segments of filament, such as but not limited to continuous carbon fiber-reinforced thermoplastic filament. Embodiments of the present invention comprises segments of filament in various geometries that distribute where adjacent segments overlap and are fused and where segments do not overlap. Embodiments of the present invention include quadrilateral (e.g., orthogonal, rectangular, etc.) infill and hexagonal (e.g., regular hexagonal, irregular hexagonal, convex hexagonal, etc.) infill.