Sinusoidal Wave Infill for Orthotics Stiffness
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Solution Overview
Problem
Conventional 3D printing infill modes, such as direction-parallel and contour infills, are inefficient in manufacturing thin-walled structures, failing to optimize weight and tailoring structural bending stiffness, particularly in custom orthotics and prosthetics, where quick production with minimal weight and specific structural properties is required.
Innovation Solution
The use of sinusoidal wave pattern infill structures within thin-walled structures, oriented normal to the boundary walls, with varying properties like amplitude, bead width, frequency, and interference, allows for localized tuning of structural properties by controlling the wave infill pattern to achieve desired mechanical characteristics in different regions of the part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional infill modes (direction-parallel or contour) are used, then manufacturing process is simple, but structural bending stiffness cannot be tailored and weight optimization is poor
Solution Approach 1:
The patent applies local quality by varying the wave infill pattern parameters (amplitude, wavelength, frequency) in different regions of the part to achieve localized control of structural bending stiffness. Different zones can have different wave characteristics tailored to specific functional requirements, allowing precise customization of mechanical properties throughout the structure.
Solution Approach 2:
The patent utilizes parameter changes by modifying wave infill characteristics such as amplitude, wavelength, frequency, and orientation in different regions. These parameter variations enable continuous tuning of structural properties like bending stiffness, strength-to-weight ratio, and energy absorption without changing the fundamental manufacturing process.
2Strength
If dense infill is used to increase structural strength, then strength improves, but weight increases and manufacturing time increases
Solution Approach 1:
The patent applies partial action by using wave infill patterns that provide sufficient structural strength only where needed, rather than uniformly dense infill throughout. The wave patterns create optimized load paths that deliver adequate strength with minimal material, reducing weight while maintaining required performance levels.
Solution Approach 2:
The patent effectively creates composite structures by combining the wave infill pattern with the boundary walls, forming a hybrid structure that leverages the strengths of both solid walls and patterned internal structures. This composite approach optimizes the strength-to-weight ratio by distributing material strategically.
3Adaptability or versatility
If uniform infill density is used, then manufacturing is simple, but localized structural property tuning is not achieved
Solution Approach 1:
The patent implements local quality through spatially varying wave infill patterns where amplitude, wavelength, and frequency parameters are customized for different regions. This enables each zone to have structural properties optimized for its specific functional requirements, achieving adaptability without uniform complexity.
Solution Approach 2:
The patent applies dynamics by making the infill pattern parameters variable and adaptable across different regions rather than static and uniform. The wave characteristics can be dynamically adjusted in the design to match varying structural requirements throughout the part.
Data Source
AI summary
Disclosed are three-dimensional parts, such as orthotics and prosthetics, having sinusoidal wave pattern infill structures first and second boundary walls. Also disclosed are printers or systems configured to manufacture such parts, as well as methods of manufacturing such parts. The sinusoidal wave pattern infill structures are formed between, and normal to, the first and second boundary walls and are configured to provide locally tunable structural properties in different regions of the part.