Variable Layer Height FDM for Optical Effects
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Solution Overview
Problem
Current 3D printing methods lack the ability to create objects with optical effects such as refraction, reflection, and transparency, and do not easily allow for controlling these effects under various light conditions, limiting their application in producing decorative and functional items like lamp shades.
Innovation Solution
A method using fused deposition modeling (FDM) that varies the layer height of 3D printed materials sinusoidally or according to other mathematical functions, allowing for the creation of objects with non-constant layer heights and widths, which can produce optical effects like transparency and refraction, and can be used to create decorative and functional items like lamp shades with wavy or triangular edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional 3D printing methods with constant layer height are used, then manufacturing simplicity is maintained, but optical effects such as refraction, reflection, and transparency cannot be achieved
Solution Approach 1:
The patent applies dynamics by transitioning from static constant layer height to dynamic variable layer height. The layer height is modified during the printing process according to mathematical functions (sinusoidal, exponential, logarithmic) to create surfaces with varying thickness that produce optical effects like refraction and reflection, while maintaining the same FDM manufacturing process
Solution Approach 2:
The patent implements parameter changes by varying the layer height parameter throughout the printing process. By changing the layer height from a constant value to a variable value defined by mathematical functions, the patent creates optical effects without changing the fundamental manufacturing method, thus resolving the contradiction between manufacturing simplicity and optical functionality
2Adaptability or versatility
If layer height is varied to create optical effects, then optical functionality is improved, but manufacturing complexity increases
Solution Approach 1:
The patent achieves universality by making the FDM printer multi-functional. The same printer that produces standard objects can now also produce objects with optical effects by simply changing the layer height parameter definition, without requiring additional hardware or complex modifications to the manufacturing system
Solution Approach 2:
The patent resolves the complexity issue by keeping the manufacturing process simple while only changing the digital parameter (layer height) that controls the optical effects. This approach maintains ease of manufacture while achieving optical functionality through software-controlled parameter variation
3Productivity
If standard FDM with uniform layers is used, then manufacturing speed is maintained, but optical effects and decorative functionality are lost
Solution Approach 1:
The patent maintains manufacturing speed by using dynamic layer height variation during the printing process. The variable layer height is implemented through software control of the extrusion process, allowing the printer to operate at normal speeds while creating optical effects through real-time parameter adjustment
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
Enables the production of 3D printed items with enhanced optical properties, such as omnidirectional depth perception and decorative light distribution, by varying layer heights to create surfaces that appear curved or have specific optical functionalities, improving the aesthetic and functional capabilities of printed objects.
Implementation Method 1
at least part of the 3D printable material comprises light transmissive polymeric thermoplastic material
Data Source
Figure 1A~1B
Figure 1C~2A
Figure 2B
AI summary
The invention provides a method for producing a 3D item (1) by means of fused deposition modelling, the method comprising a 3D printing stage comprising layer- wise depositing an extrudate (321) from 3D printable material (201), to provide the 3D item (1) comprising 3D printed material (202), wherein the 3D item (1) comprises a plurality of layers (322) of 3D printed material (202), wherein each layer (322) has a layer height (H) and a layer width (W), wherein the 3D printing stage comprises generating a stack (1322) of the layers (322) of the 3D printed material (202), wherein at a fixed first x,y-position the layer height (H) is varied layer by layer for a subset of a total number of layers (322), wherein either (i) the layer height (H) increases for consecutive layers (322) and then the layer height (H) decreases for consecutive layers (322), or (ii) the layer height (H) decreases for consecutive layers and then the layer height (H) increases for consecutive layers (322); and wherein at least part of the 3D printable material (201) comprises light transmissive polymeric thermoplastic material (401).