3D Printer Sparse Infill Structure for Weight Reduction
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Solution Overview
Problem
Existing 3D printing technologies face challenges in reducing build time, part cost, and weight, especially for larger parts with complex internal structures.
Innovation Solution
A method and apparatus for operating a 3D printer to fill internal volumes of three-dimensional objects using a sparse infill structure, which involves determining the number of layers required, forming floor and roof layers, and using a maximum individual stepout distance to generate instructions for forming sloped edges of a sparse infill structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional solid infill structure is used to fill internal volume of 3D object, then strength and rigidity are maintained, but build time increases and material cost increases
Solution Approach 1:
The internal volume is divided into multiple discrete layers with strategic solid infill (floor and roof layers) rather than continuous solid infill. The floor layers provide structural foundation, the roof layers provide structural closure, and the intermediate layers use sparse patterns, segmenting the infill approach to optimize both strength and build time
Solution Approach 2:
Different infill densities are applied to different regions and layers of the internal volume. Floor layers and roof layers use solid or dense infill for structural integrity, while intermediate layers use sparse infill patterns. This local variation in infill quality maintains strength where needed while reducing material and build time in less critical regions
Solution Approach 3:
Instead of applying solid infill throughout the entire internal volume (excessive action), the patent applies solid infill only partially - specifically in floor and roof layers where structural integrity is most critical. The intermediate layers use reduced sparse infill, achieving sufficient strength with less material and faster build time
2Strength
If traditional solid infill structure is used to fill internal volume of 3D object, then strength and rigidity are maintained, but material cost increases
Solution Approach 1:
The infill structure is segmented into floor layers, roof layers, and intermediate layers with different material densities. This segmentation allows material to be concentrated where structurally necessary (floor and roof) while minimizing material in intermediate sections, reducing overall material consumption while maintaining strength
Solution Approach 2:
Material quantity is optimized by applying different infill densities to different local regions. Solid infill is used locally in floor and roof layers where strength is critical, while sparse infill is used in intermediate layers where less material is needed to maintain structural integrity, thereby reducing total material use
Solution Approach 3:
The patent applies material partially rather than excessively throughout the entire internal volume. Solid infill is applied only in the portions (floor and roof layers) where structural strength is most critical, while intermediate layers use minimal sparse infill, achieving the necessary strength with significantly reduced material consumption
3Strength
If traditional solid infill structure is used to fill internal volume of 3D object, then structural integrity is maintained, but weight increases
Solution Approach 1:
The internal volume is segmented into floor layers, roof layers, and intermediate layers with varying infill densities. This segmentation creates a lightweight structure where material is concentrated in floor and roof layers for structural integrity while intermediate layers use sparse infill to minimize weight, achieving strength-to-weight optimization
Solution Approach 2:
Different infill densities are applied locally to different layers to optimize the strength-to-weight ratio. Floor and roof layers use solid or dense infill for structural integrity, while intermediate layers use sparse infill to reduce weight. This local quality variation maintains structural integrity while minimizing overall part weight
Solution Approach 3:
Material is applied partially rather than excessively throughout the internal volume. Solid infill is used only in floor and roof layers where structural integrity is critical, while intermediate layers use minimal sparse infill. This partial application of material maintains necessary structural integrity while significantly reducing part weight
4Productivity
If maximum individual stepout distance is used to generate machine-ready instructions, then build time is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent optimizes the maximum individual stepout distance parameter in the machine-ready instructions to balance build time and precision. By carefully selecting this parameter, the printer can move efficiently between droplet ejection positions while maintaining sufficient precision for proper droplet placement and layer bonding, achieving both fast build time and acceptable manufacturing precision
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
The sparse infill structure reduces build time, part cost, and weight by using less material while maintaining the strength and rigidity of the printed parts, making it suitable for large-scale parts in industries like aerospace and automotive.
Implementation Method 1
One particular type of 3D printer is a magnetohydrodynamic (MHD) printer, which is suitable for jetting liquid metal layer upon layer which bond together to form a 3D metallic object. Magnetohydrodynamic refers to the study of the magnetic properties and the behavior of electrically conducting fluids.
Data Source
AI summary
A method of operating a printer to fill an internal volume of a three-dimensional object is includes determining a total number of layers required to fill an internal volume of a three-dimensional object, forming at least one floor layer within the internal volume, using a maximum individual stepout distance to generate machine-ready instructions that operate the printer to form one or more pre-determined sloped edges of a plurality of sections of a sparse infill structure in the layer of the internal volume to be filled, thereby forming at least one sparse infill layer. A drop ejecting apparatus includes a controller operatively connected to a reservoir, an ejector, and at least one actuator, the controller being configured to perform the method as described herein.