Variable Density Lattice for Additive Manufacturing Structural Support
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Solution Overview
Problem
Three-dimensional manufacturing systems face challenges in minimizing material usage and print time while maintaining structural integrity, particularly in the creation of sacrificial articles for investment casting.
Innovation Solution
The method involves defining a lattice structure within a three-dimensional article using a processor and information storage device to confine the lattice to a specific volume, minimizing material usage while providing structural integrity, by using a varying density lattice with an outer and inner lattice, and a cage mesh for added support, allowing for efficient material usage and rapid resin drainage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a full lattice structure fills the entire inner cavity to provide structural support, then structural integrity is improved, but material usage and print time increase
Solution Approach 1:
The patent applies local quality by implementing variable density lattice structures where different regions have different lattice densities. The outer lattice volume near the shell uses higher density for structural support, while the inner volume uses lower density or is completely removed. This allows the structure to have sufficient strength where needed while minimizing material usage in less critical areas.
Solution Approach 2:
The patent segments the internal volume into distinct regions: an outer lattice volume between the shell and a boundary surface, and an inner volume inside the boundary. By confining the lattice to only the outer lattice volume and leaving the inner volume empty or with minimal structure, the design provides structural support where necessary while dramatically reducing overall material consumption and print time.
2Productivity
If material usage is minimized to reduce cost and print time, then manufacturing efficiency is improved, but structural integrity deteriorates
Solution Approach 1:
The variable density lattice structure implements local quality by concentrating material where it provides maximum structural benefit. The outer lattice volume maintains higher density to support the shell and maintain dimensional control, while the inner volume uses reduced or zero material. This localized material distribution preserves structural integrity in critical areas while minimizing overall material usage and print time.
Solution Approach 2:
The patent applies partial action by providing lattice structure only in the outer lattice volume rather than filling the entire inner cavity. This partial lattice confinement provides sufficient structural support for shell stability and dimensional control during printing and burnout processes, while avoiding the excessive material usage and extended print time that would result from complete cavity filling.
3Quantity of substance
If the lattice is confined to the outer lattice volume to minimize material, then material usage is reduced, but structural support capability may be compromised
Solution Approach 1:
The patent implements local quality by positioning the lattice structure specifically in the outer lattice volume where it provides maximum structural support for the shell. The boundary surface is strategically positioned to ensure that all critical load-bearing regions are within the outer lattice volume, allowing the lattice to provide sufficient support while minimizing material usage by excluding the inner volume.
Solution Approach 2:
The patent utilizes the spatial dimension by carefully positioning a boundary surface that divides the inner cavity into an outer lattice volume and an inner volume. By confining the lattice to the outer region and using the boundary surface as a transition, the design achieves efficient material distribution that maintains structural support capability while minimizing overall material consumption.
4Manufacturing precision
If a dense lattice structure is used to ensure dimensional control, then manufacturing precision is improved, but material usage and print time increase
Solution Approach 1:
The patent applies local quality by implementing higher lattice density specifically in the outer lattice volume where dimensional control of the shell is critical. The lattice structure in this region provides the necessary support to maintain shell geometry and prevent deformation during printing and subsequent processing. The inner volume uses reduced or zero material, achieving dimensional control where needed while minimizing overall material usage.
Data Source
AI summary
An apparatus for manufacturing a three-dimensional article by additive manufacturing includes a processor and an information storage device. The information storage device includes a non-transient or non-volatile 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 boundary in the inner cavity that further defines an outer lattice volume between the inner surface of the shell and the boundary and an inner volume inside the boundary, and define a lattice that fills the outer lattice volume.