Infill Design Reinforcement of 3D Printed Parts Using Refinement Technique Adapted to Continuous Extrusion

• Main Authors: Sashi Kiran Madugula, Laurence Giraud-Moreau, Pierre-Antoine Adragna, Laurent Daniel
• Format: Article
• Language: English
• Published: MDPI AG 2021-07-01
• Series: Journal of Manufacturing and Materials Processing
• Subjects: infill structure; continuous printing; additive manufacturing; refinement; finite element simulation (FE Simulation); fused deposition modelling (FDM)
• Online Access: https://www.mdpi.com/2504-4494/5/3/71

In this paper, we introduce an advanced numerical tool aimed to optimise the infill design of 3D printed parts by reducing printing time. In 3D printing, the term infill refers to the internal structure of a part. To create the infill design, slicing software is used, which generally creates the infill uniformly throughout the part. When such a part is subjected to external loading, all the infill regions will not experience the same amount of stress. Therefore, using uniform infill throughout the part is not the most optimised solution in terms of material usage. We do propose to evolve the infill design with respect to the mechanical stresses generated by the external loads. To achieve this, an advanced numerical tool has been developed, based on refinement techniques, to control the infill design. This tool is coupled with Finite Element Simulation (FE Simulation) software, which helps to identify the zones where the material is required as an infill to reinforce a part, whereas the refinement technique makes it possible to place the material as an infill in such a way that the airtime during the printing of the part is zero. Zero airtime printing is defined as the ability to deposit each layer of a part, without stopping the material extrusion during the displacement of the nozzle. Therefore, the proposed numerical tool guides us to generate the infill design of a part, in such a way that it will consume zero airtime while manufacturing. Simultaneously, it will increase the stiffness of the part. The proposed approach is here applied to a rectangular structure subjected to four-point bending, made up of PLA material (Poly-Lactic Acid).