V-Shaped 3D Printing Support Structures with Lattice Infill
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Solution Overview
Problem
Conventional 3D printing processes often require excessive support structure material, which increases costs and time, as they typically print solid support structures that exceed the threshold overhang angle, leading to non-value added material and inefficiencies.
Innovation Solution
A method and apparatus for forming optimized temporary support structures in 3D printing using a computer-controlled 3D printer, which identifies areas exceeding the threshold overhang angle and generates V-shaped cap portions with infilled gussets or low-density material, minimizing material usage while providing adequate support, and includes a virtual support web to reduce material requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional solid support structures are used to support model areas exceeding the threshold overhang angle, then adequate support is provided during printing, but the volume of support material used increases significantly (often equal to or more than the target model material)
Solution Approach 1:
The patent applies porous lattice structures instead of solid support material. The lattice structure provides sufficient support strength while dramatically reducing material volume through its open-cell geometry, allowing gaps that reduce material consumption while maintaining structural integrity during the printing process
Solution Approach 2:
The patent uses composite support structures combining different materials - a solid or lattice outer shell providing structural strength, and an infill material (such as air, foam, or different density material) inside. This composite approach optimizes the balance between support adequacy and material reduction
2Reliability
If monolithic support structures extending vertically to all support locations are printed, then comprehensive support is provided, but the printing time and material cost increase considerably
Solution Approach 1:
The patent segments monolithic support structures into discrete lattice units or modular sections. This segmentation allows for optimized printing paths, reduced material deposition time, and enables parallel processing of different support regions, thereby improving overall printing efficiency while maintaining comprehensive support coverage
Solution Approach 2:
The patent implements partial support structures that provide support only where and when needed, rather than continuous monolithic support. The lattice structures are strategically placed and sized to provide adequate support during critical printing phases while minimizing unnecessary material deposition and printing time
3Reliability
If support structures are designed to exceed the threshold overhang angle for maximum support coverage, then all model areas are supported, but the amount of non-value added material increases
Solution Approach 1:
The patent applies local quality by varying the support structure properties in different regions. Lattice density, cell size, and structural configuration are locally optimized based on the specific support needs of each model area, providing adequate support where required while minimizing material usage in areas with lower support demands
Solution Approach 2:
The patent changes key parameters of the support structures including lattice cell size, wall thickness, infill density, and material composition. By optimizing these parameters, the support structures achieve the minimum necessary support functionality while minimizing material consumption, reducing waste without compromising support completeness
Data Source
AI summary
A printed target model is formed by 3D printing by inputting target model data, and based on target model data, identifying surface portions requiring support. The surface portions are projected onto a virtual printer table, and one or more virtual support structures having a V-shaped cap portion and optionally a generally planar web are created therefore. The virtual model is then used to control a 3D printer to integrally print-form the target model and support structures.