Shell-Lattice Transition Zone for 3D Printing Resin Drainage
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Solution Overview
Problem
Three-dimensional manufacturing systems face challenges in providing adequate support to maintain accurate geometries while minimizing unsolidified material, particularly in the transition zone between a shell and a lattice, which can trap resin and cause damage during the burn-out process.
Innovation Solution
The method involves defining a transition zone between the shell and the lattice with transition segments oriented perpendicular to the shell's inner surface, facilitating resin drainage and providing uniform support, and using a lattice structure with intersecting segments to minimize polymer material usage, coupled with a mesh cage for flexibility in density and location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a lattice structure is used to support the shell, then structural support is improved, but resin drainage is hindered due to trapped unsolidified material in the transition zone
Solution Approach 1:
The lattice structure is segmented into two distinct zones: a first lattice structure in the support region with higher density for structural support, and a second lattice structure in the transition zone with lower density for resin drainage. This segmentation allows each zone to fulfill its specific function without compromising the other.
Solution Approach 2:
Different lattice structures are applied to different regions of the shell. The support region receives a dense lattice for maximum structural support, while the transition zone receives a sparse lattice that facilitates resin drainage. This local differentiation resolves the contradiction by optimizing each region for its primary function.
2Productivity
If the transition zone is minimized, then manufacturing efficiency is improved, but resin drainage is compromised leading to trapped material
Solution Approach 1:
The transition zone is strategically positioned only in areas where geometry changes occur, such as near openings or varying wall thicknesses. In regions with uniform geometry, the lattice transitions directly without an intermediate transition zone, maintaining manufacturing efficiency while preventing resin trapping where necessary.
3Strength
If a dense lattice structure is used throughout, then shell support is improved, but polymer material usage increases
Solution Approach 1:
The lattice structure is divided into a dense first lattice in the support region and a sparse second lattice in the transition zone. This segmentation concentrates polymer material only where structural support is critical, reducing overall material usage while maintaining shell support integrity.
Solution Approach 2:
A dense lattice is applied locally to the support region where shell support is needed, while the transition zone uses a sparse lattice. This localized application of density optimizes material distribution, providing sufficient support where required while minimizing polymer consumption in areas where drainage is the priority.
Data Source
AI summary
An apparatus for manufacturing a three-dimensional article by additive manufacturing includes a processor and an information storage device storing software instructions. In response to execution by the processor, the software instructions cause the apparatus to: receive initial data defining the three-dimensional article having an outer surface, define a shell having the outer surface of the three-dimensional article and an opposing inner surface that defines an inner cavity, define a transition zone between the inner surface of the shell and a boundary that is inside the inner cavity and generally follows the inner surface of the shell, define a lattice of arrayed unit cells that fill the inside of the boundary, the lattice is defined by connected lattice segments, and define transition segments that couple the lattice to the inner surface of the shell.