Load dependent Infill placement: Smart Infill for FDM 3D prints!
ฝัง
- เผยแพร่เมื่อ 28 พ.ค. 2024
- Let me show you how you can optimize the infill structure of your 3D printed part according to the applied loads. We'll use Fusion 360 and ANSYS Finite Element Simulation to create custom modifier meshes to efficiently adjust the internal structure of our 3D prints.
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You never fail to come up with interesting technical ideas for videos. Well done Stefan.
Amazing workflow. I only wish that you had a 100% dense model to compare strength to weight to material cost.
Didn't want to show that hours of adjusting settings could be beaten by yeeting more material out of the nozzle 😆. The weight comparison is nice. But unless it's flying I never cared.
I agree. Strength to weight ratio would be the best way to show the efficiency of this process.
@@mattweger437 Weight = Printing time ;)
What an awesome technique! It seems useful for being super efficient with your materials if using an expensive filament or printing a lot of copies of a model, or just for adding a visual detail like the dual color versions you printed. Also, thanks for confirming my intuition that adding perimeters is generally more effective than increasing infill, that little test alone made this worth watching :)
also, it's a great way to show stresses in r&d with multicolor printing.
This is just an accessible version of 'Discontinuity Layout Optimisation' used when designing engineering structures / parts.
He did made a video quite long time ago, that prooves the higher perimeter betten than more infill.
Will you use this in your projets?
On the chance you read through new comments on old videos. A video highlighting whether or not going through that process with the previously strengthened completed hook to see if it will improve it any further.
Yay! Always excited for real engineering in 3D printing content!
The computer can run Crysis, but can it run f i n e m e s h s i m u l a t i o n ?
i only simulate my fine mesh at 120fps
As a 3D printing hobbyist and a mechanical engineer I can say this is Fxxxing brilliant, the applications are so vast
What we need is a finite mesh simulation that outputs a weighted mesh that gives the stresses as a proportion of maximum. Then we need slicer integration that will allow you to create gradient infill according to a curve. That way we get better fading between infill strengths so that the load is distributed more evenly and we can fine tune the process at the end instead of restarting each time.
Distributing the load would probably help a ton because it looked like some of the parts began to fail when the internally dense region began separating from the rest of the part. If it could be faded more evenly to distribute load, possibly with custom infill shapes to spread forces into the whole of the part, I bet the part could be made even stronger at the same weight.
Effectively, I think what a large goal should be for the 3D printing community is for us to move away from static infill patterns to infill that is created procedurally for each part to maximize load distribution. I'm imagining a version of infill that has almost that tree-like branching that moves from a thick area near the main stress in a direction that will support the part and then spreading and splitting outward to spread out that load. 3D printing could allow us to, in a way, create parts that have fully connected fiber reinforcement aligned to maximize strength.
I'd imagine optimizing the filament paths is probably harder than just density. Although optimized paths will likely perform notably better than pure density. Especially since strength in various orientations differs non linearly for orientation and density. However, there's already ongoing research into fiber orientation optimization for high end carbon fibre structures... just need some of that for 3d print software.
Spot on. The vertical gradient between 100% infill and 10% infill was a stress riser. Interpolate over some range at the boundary and it'll be stronger.
Building off of this concept, I imagine it would be helpful to have different types of material within the model. PLA and flexible in the same model might provide many advantages.
@Vivid Media Need to complete the loop: AI needs to be trained, AND you would want some sort of feedback loop to improve its performance.
As someone interested in simulation (via OpenFOAM and SimScale), this was incredibly fascinating! More like this please!
I'm interested
I think I'd like to see more on the shape optimization using multiple materials. In the video you show the one printer printing the hook with the optimized infill in a different color. Instead of another color use a stronger material. So for the base hook body maintain the standard PLA and then for the reinforcements use one of the PLA filaments that has adders in it, or print that section with say ABS or Nylon. I am not sure how the two material bonding would react but it would allow you to use a cheaper material for the base part and then a stronger but pricier material for the areas that need the reinforcements. Similar to some injected molded parts where there are metal reinforcements in critical sections of the model (one thing that comes to mind is metal reinforced feed lips on polymer AKM magazines).
Great work as always sir, from one engineer to the other, I love the way you structure these videos and tests.
Good idea, but rather than different plastics which print at drastically different temps I would suggest reinforced vs non-reinforced plastics. I.e. use standard cheap pla for most of the part, but on the high-stress regions use carbon fiber/ Kevlar/ cellulose reinforced pla.
@eugenioLU91 I haven't seen that, however I question whether you're thinking of structural or decorative pla. Either way it's a better place to start than attempting to print abs into pla (which will melt straight through the surrounding pla producing little more than plastic blobs).
@@xxportalxx. PET-G and other copolymers can print at about the same temp (250) as CF-nylon so this might be an interesting combo.
@@robertasumendi I haven't had opportunity to use much of either, however the ability to mix materials seems like a promising niche for additive manufacturing.
Personally I've been spending more time researching the potential of printing protoboards easier (as an ee that is more aligned with my use case)
Also adding in flexible filament and seeing the affects of that.
You are my gurú! i work in a 3D printing laboratory here in México ,so whenever you come to Yucatan you have a room reserved in my home! you inspire us buddy!
Wow, this video is amazing! I really think this kind of work unlocks the potential of 3D printing to use material effectively.
This is outstanding! GREAT work. Thanks for sharing. I've worked with topology optimization for my master degree, studying the application of top-opt techniques in the early phases of an industrial design project (how to deal with style, ergonomy and so on…). This is such a clever application!
Those results were both enlightening and impressive. Thanks for sharing and keep up the good work.
Boom! This is so great. We were just talking about this in the studio yesterday. So awesome. Love the style and speed of this video! Great work!
Very awesome information! I have been playing around with cresting my own infil directly into the design and leaving out infill from my slicer.
This is very similar and I'll be playing with it.
Very interesting solution and very impressive results! This would be an important add-on plug-in for slicers.
This is really cool !
Exporting the optimized mesh and using modifiers is quite a nice workflow
Impressive work you have done
Thanks for sharing👍😀
Oh man, I love this stuff! I've already learned so much useful information from your channel. Thanks for all you do! 🙂
Amazong work Stefan, I love learning this type of stuff from your channel. Just superb! Thank you!
Excellent video. Thank you for doing the hard work. I may put these concepts in mind when designing my next load bearing project.
This is genius-level. So good! Can’t wait to try this out.
You're a smart young man Stefan. I'm new to 3d, just having gotten my first printer last week, but have been watching your shows for quite some time. I Love your content man!!!
Wow... This was great. Kudos for this video - you constantly keep getting better. This is easily you best video, yet. Both in technical- as also in presentation terms. Keep up with your great work!
This is definitely one of the great advantages 3D printing can offer, excellent video!
Excellent video Stefan. I love videos that mesh 3D printing and stress analysis. Thank you.
You just blew my mind. A brilliant idea. All I can say is thank you.
This is one of the best things I've seen in 3d printing in the last few years.
Nice. I like that the reinforced ones show distortion some time before failure. Sounds like a good safety feature to me.
You really bring value to the 3d print community. This was super interesting, i'm going to test it
This is SOOO COOL !!!! Thank you so much for teaching us how to do this!
YOU ARE AMAZING!
This video was incredible. Probably the one I've enjoyed the most. Thanks
You are awesome Stefan! This bloody useful for me, because I do a ton of practical 3d printing.
This looks super useful. Think I might give it a shot and see if I can use it in future prints.
Nice video, good to be back at school sometimes and learn really interesting things! Thanks!
It's obvious the reason why the "full optimized" design was strongest is because it delaminated before it could fail in tension. That allowed the structure to deform and relieve some stress.
That's one hell of an engineering project, Stefan. Brilliant job!
Wow, this is really useful. Gonna try this asap for some of my mechanical designs.
Very interesting. I cant help but wonder how this compares to 100% fill of the whole hook. Also, then reduce the thickness or width of the hook to get back to the same weight at 100% fill.
This is an amazing video!!! I really appreciate the work you into it and it's a testament to how proper engineering techniques can yield great results.
At a bare minimum, any part I print that requires strength will likely be the 5 perimeters/10% infill, which seems to be a nice labor/strength improvement tradeoff.
Danke für die interessante Ingenieurssicht, ohne Staubfänger ;-)
Impressive work there, I really appreciate your work.
It would be interesting to see how the smart infill pieces strength compares with itself, after annealing them. Great video and awesome technique, hope to see (and test) more of this!
Sehr spannend. Danke für die kurze fusion Anleitung.
One of the best 3dprinting videos I've ever seen.
Nice Work!! Quadcopter arm sounds interesting
Top quality content, as always. Thanks for your work!
Thank you for your effort, this is really usefull and inspiring. Keep up the great work!
this was really informative, been wondering how to use optimization simulations in 3D printing and now i know. Thank you.
Time to awaken my inner child and start playing around with it. :D
Terrific, thanks for sharing your brillant research!
Awesome work! Thank you for that video.
Amazing! :o
Thanks from all the 3d-printing architecture students!
Great channel, great video. At last someone who does real technical evaluation rather than just a personal opinion. Respect to a real maker.
Quadcopter arm optimization would be awesome
I was thinking exactly the same thing!
Yeah, but that would be really hard. The case where quadrocopters break usually is in a crash, so in my opinion you would have to optimize for this case. Using this method with FEM simulation, you only optimize for ONE case, usually where the force is one way and constant... Also in flight, the forces vary, if you change direction, because of inertia (Trägheit). So you would have to combine optimized infills of many cases. That might be interesting.
SUPER! As always:) I really appreciate your rigor. Thx, sincerely.
I was just working on a functional print and this came up, which is exactly what I needed since it keeps breaking at a certain area
Top quality work, keep innovating!
What an interesting group of thought/structural experiments. I'll have to keep those tricks in mind.
One thing I've done for parts that I need to tap (When we make samples of castings at work) I cut a bunch of .02mm lines radially around the hole so that the printer does a zigzag pattern around the hole to be tapped. This way I can force plenty of solid plastic around the hole to finish drill and tap without having to up the perimeters everywhere else.
Great, this is basically using the "virtual fiber" technique!
Thank you for sharing! Great topic.
A very simple way of adding the smart infill :). Great work!!! An idea I came up with, but lack of time has stopped me :(. I was looking into using a basic fractal branching set of connected rods like bone. So the sides can spread the stress more evenly. I also think it’d help if the part was PLA and baked. As to what part you should try, I vote for the quad copter ;)
I liked the video the moment I saw the display picture 👌😄
Superp efforts and amazing information and techs. Keep it up!
Slingshot might be a good demonstration object. Interesting shape, several load and structure positions, exciting results when they fail.
Excellent research Stefan!
Great work as usual! :)
Yep, gotta subscribe to this. Thanks for the content!
Damn, really impressive! I would love too see further research in this direction :)
great, thanks fpr the time spent researching and sharing
Next level stuff. Nicely done.
As usual, high tech 3d printing. Good job sir :)
Thanks to share it with us!!! Great job!
Great Experiment!
It was a awesome idea!
This is very cool. Great job!
wow man you really make some great videos. thank you.
Great Idea! I used Simplify3D and 2 combined "layer by layer" print processes (The main model with a sparse infill and the optimized meshbody .obj at 100%) with a similar result.
In S3D one can just import the "optimized" .obj file as a "modifier" file.
Very interesting video! Keep up your good work!
Absolutely fascinating.
Great work! Congrats 👍
Fantastic video, I never knew that modifier thing in Slic3r was a thing! Definitely going to try this now, thank you(:
Love it! Not much else to say - great job.
That's the most interesting addition I've seen since the last few years in 3d printing. It would be really nice if this feature would be added directly to the slicing softwares. It would be nice to see the increase of streingth of a 3d printed object combining the effect of optimized infill and copper electroplating.
this is SO promising. great work.
This is gold. Thanks
This is really interesting. We've been using Slic3r's volume-based variable infill to solve issues with part strength so I'll give this a go and test the relative differences in strength. Thanks!
Great, let us know your results.
Ive done stuff like this in the past with Fusion. Never tested like you did but you did a great job explaining the process along the way. As for the gaps on concentric infill, what about using a larger nozzle diameter and low layer heights? This will effectively reduce any voids in the part. Also in fusion you can modify the shape optimization criteria for a higher target mass so you can get an optimization that is all connected. Which will likely reduce voids going from solid reinforcement to infilled spaces.
I think you are awesome! Very nice vid man! Great knowledge
Interesting hack of the FEA!
Neat! I already do that with my prints of I know there is a point which will need reinforcement.
Brilliant! Well done!
Interesting. Thank you!
Great video, thank you!
Stefan, you are great !
That was a significant strength increase, fascinating topic.
Also a great way to optimize. Most strength for minimum material.
What I'm curious to know is what would the strength test be if you made the entire part with 100 percent infill. Feel like this would give you an upper limit on what's possible in terms of strength with the given material, and provide you with an idea of how close you can get to a theoretical maximum strength.
This is some good 3D printing content!
Very, very clever. Bravo!
Very nice video!
Outstanding!
Such. Good. Content!
As someone familiar with the use of FEA this is an interesting topic and workflow. It would be interesting to see how the parts reacted when subjected to loads that it wasn't optimized for compared to the standard infill parts. At least with a hook it's fairly easy to know how the part will be loaded, but sometimes parts can be subjected to loads that you may not suspect, hence the need for safety factors. However, I'm sure this consideration is probably overkill when you're worried about hobby projects, but something to keep in mind nonetheless.
Thank you!