Researchers achieve 90% reduction in 3D printing processing times
An international team has developed a new method for laser-based powder bed fusion, which utilizes a hybrid toolpath that bypasses the need for STL file format
Members of the team, including those from the Chinese University of Hong Kong, the University of Southern California, and other institutions, developed a method that eliminates cumbersome file sizes and imprecise geometric estimates—issues often associated with STL file formats.
The result is that lattice shapes are turned straight into laser paths for the printer, skipping the STL file step that causes delays and problems. STL files have been used to convert digital designs into printable layers for years, but have always had limitations in delivering high-resolution, precise, and structurally sound implementations in the design-to-print pathway, despite constant innovation in the STL space.
The team’s solution completely negates the STL step of the process by directly feeding a mathematical description of geometries into the 3D printer.
In addition to a 90% reduction in memory and processing times, the foregoing of the traditional mesh-based STL workflow also enables high-fidelity fabrication of microscale shell lattices. The team claims a 66% increase in yield strength and a 257% increase in elongation.
The researchers also said that the new process produced a lightweight aerospace bracket with 52% greater tensile strength, which could absorb five times more energy before breaking than parts made with traditional methods. The potential applications are multiple, according to members of the team.
“Our method bridges computational design and physical fabrication in a seamless way,” Wen Chen, Associate Professor of Aerospace and Mechanical Engineering and Materials Science at the University of Southern California, said. “It opens up new possibilities for high-performance microscale structures in fields like aerospace, biomedicine, and electronics.”
Xu Song, Associate Professor at Chinese University of Hong Kong, added: “By bypassing STL conversion and operating directly on implicit functions, we reduce memory usage and also unlock far better mechanical and surface properties”.
