3D Printed Volume Chamber Components with Filler Material
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current 3D printing methods are inefficient and inflexible in producing components with desired mechanical properties, as they require continuous application of printing material over the entire surface for solid body portions, leading to prolonged manufacturing times and limited ability to adjust properties.
Innovation Solution
The method involves initially printing the outer contour of a component layer with volume chambers, which are then partially or fully filled with filler material in a separate step, allowing for targeted mechanical property optimization by varying the filling of volume chambers with different materials and patterns, and using process parameters to ensure integration with the outer contour without deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous application of printing material is used over the entire surface for solid body portions, then the component structure is complete and solid, but the manufacturing time is prolonged and material usage is high
Solution Approach 1:
The solid body portion is segmented into multiple volume chambers that are distributed throughout the component. Instead of continuously printing material over the entire surface, the extruder creates discrete volumetric chambers that are then filled with filler material, significantly reducing printing time while maintaining structural integrity
Solution Approach 2:
The outer contour and volume chamber structure are printed first as a preliminary framework, and only after this structure is in place is the filler material introduced to complete the solid body portions. This preliminary action allows the extruder to define the complete geometry before filling, ensuring structural completeness without requiring continuous material application throughout the entire process
2Reliability
If continuous application of printing material is used over the entire surface, then the component structure is complete, but the material usage is high
Solution Approach 1:
The solid body portion is divided into multiple discrete volume chambers rather than being printed as a continuous solid. This segmentation allows the extruder to deposit material only where needed to form the chamber boundaries, and the remaining volume is filled with filler material, significantly reducing the quantity of printing material required
Solution Approach 2:
Printing material is applied locally to form the outer contour and volume chamber boundaries, rather than being applied continuously over the entire surface. The filler material then fills the remaining volume, creating a material-efficient construction where each material type is used only where structurally necessary
3Ease of manufacture
If standard 3D printing methods are used, then the manufacturing process is simple, but the ability to adjust mechanical properties is limited
Solution Approach 1:
Different regions of the component can have different filling configurations - some volume chambers can be completely filled, partially filled, or left empty, allowing local variation in mechanical properties. The extruder can be programmed to create different chamber patterns and filling densities in different areas of the component
Solution Approach 2:
The manufacturing process becomes dynamically adjustable by controlling the filling of volume chambers. The extruder can vary parameters such as filling quantity, filling pattern, and chamber configuration during printing, enabling real-time adjustment of mechanical properties without changing the basic manufacturing process
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
This approach accelerates the 3D printing process, reduces material usage, and enhances mechanical properties by enabling partial or complete filling of volume chambers with specific materials, achieving higher strength and density while maintaining the integrity of the outer contour.
Implementation Method 1
by means of an extruder, and here in particular at least one extruder screw provided within the extruder, for example metal, ceramic and/or plastics granulate is the melted and conveyed to a print head of the extruder
Implementation Method 2
by means of an extruder, and here in particular at least one extruder screw provided within the extruder
Implementation Method 3
in at least one following, second work step, the at least one volume chamber is filled with a filler material, at least in part
Implementation Method 4
the at least one volume chamber is filled with a filler material
Data Source
AI summary
It is provided a method for the additive manufacturing of a component, wherein the component is constructed in a layered manner by means of at least one extruder of a 3D printing device. In the additive manufacture of at least one component layer of the component, by means of the at least one extruder in a first work step, initially an outer contour of the component layer is produced, which extends in a layer plane and comprises at least one outer wall which extends in an extension direction perpendicular to the layer plane and is intended for bounding a volume region at least in part, wherein at least one volume chamber that is open in an extension direction is formed within the volume region, and in at least one following, second work step, the at least one volume chamber is filled with a filler material, at least in part.