Surface Lattice Formation for Accurate 3D Printed Geometry
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Solution Overview
Problem
Additive manufacturing of lattice structures with complex geometries results in incomplete or hanging beams at the external surface, leading to deviations in shape and mechanical properties, which adversely affect user experience.
Innovation Solution
A surface lattice structure is formed to connect with a trimmed lattice structure, recreating the surface geometry and properties by deriving connection information from sub-volumes split by beams, and combining it with the lattice infill to form a combined lattice structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing is used to produce lattice structures with complex geometries, then manufacturing flexibility and design freedom are improved, but incomplete or hanging beams form at the external surface causing deviations in shape and mechanical properties
Solution Approach 1:
The method performs preliminary identification of incomplete or hanging beams at the external surface of the lattice structure before finalization. By detecting these defective beams in advance and regenerating them to connect with the surface, the system prevents shape deviations and mechanical property losses before they occur, thereby maintaining both design freedom and shape accuracy.
2Adaptability or versatility
If additive manufacturing is used to produce lattice structures with complex geometries, then manufacturing flexibility and design freedom are improved, but incomplete or hanging beams form at the external surface adversely affecting mechanical integrity
Solution Approach 1:
The system identifies incomplete or hanging beams at the external surface before final structure completion. By regenerating these beams to properly connect with the surface, the method prevents mechanical integrity failures before they occur, allowing complex geometries to be produced without compromising strength.
Solution Approach 2:
The method implements a feedback mechanism where the lattice structure is analyzed to identify defective beams, and regeneration operations are performed based on this feedback. This closed-loop approach ensures that mechanical integrity is maintained by continuously monitoring and correcting beam connections at the external surface.
3Productivity
If traditional lattice structure generation methods are used, then processing speed is maintained, but incomplete beams at the surface lead to deviations in mechanical properties
Solution Approach 1:
The system performs preliminary identification and regeneration of incomplete beams at the external surface during the lattice structure generation process. This preliminary action ensures mechanical property consistency without requiring complete reprocessing, thereby maintaining productivity while improving reliability.
Data Source
AI summary
In some examples, a system defines sub-volumes within a bounding object based on beams of a unit cell of a lattice structure for a 3D object to be built. The sub-volumes are defined based on the beams cutting through the bounding object that contains the unit cell. The system intersects the sub-volumes of the bounding object with a trimmed version of the lattice structure. The system forms a surface lattice structure having beams identified based on the intersecting, the beams of the surface lattice structure to connect to unit cells of the trimmed version of the lattice structure.