Method of additive manufacturing an internal wave sparse structure with varying geometry for localized tunable structural properties throughout a part

Abstract

Disclosed are three-dimensional parts, such as orthotics and prosthetics, having sinusoidal wave pattern infill structures first and second boundary walls. Also disclosed are printers or systems configured to manufacture such parts, as well as methods of manufacturing such parts. The sinusoidal wave pattern infill structures are formed between, and normal to, the first and second boundary walls and are configured to provide locally tunable structural properties in different regions of the part.

1 . A three-dimensional orthotic or prosthetic part printed using an additive manufacturing technique, the three-dimensional part comprising:
 a thin-walled structure having first and second boundary walls defining a contour of the part; and   a sinusoidal wave pattern infill structure formed between the first and second boundary walls and configured to provide locally varying and tunable structural properties in different regions of the part.   
     
     
         2 . The three-dimensional orthotic or prosthetic part of  claim 1 , wherein the sinusoidal wave pattern infill structure has a sinusoidal wave pattern oriented normal to the first and second walls of the thin-walled structure. 
     
     
         3 . The three-dimensional orthotic or prosthetic part of  claim 2 , wherein the sinusoidal wave pattern infill structure has a plurality of variable properties, and wherein at least one of the plurality of variable properties of the sinusoidal wave pattern infill structure is varied throughout the part to locally tune structural properties in different regions of the part. 
     
     
         4 . The three-dimensional orthotic or prosthetic part of  claim 3 , wherein the plurality of variable properties include sinusoidal wave pattern amplitude corresponding to part thickness, beadwidth, frequency, and interference with the first and second boundary walls. 
     
     
         5 . The three-dimensional orthotic or prosthetic part of  claim 4 , wherein the frequency of the sinusoidal wave pattern is varied throughout the part to locally tune structural properties in different regions of the part. 
     
     
         6 . The three-dimensional orthotic or prosthetic part of  claim 2 , wherein the sinusoidal wave pattern is continuous as the frequency is varied. 
     
     
         7 . A method for printing a three-dimensional part with an additive manufacturing system, the method comprising:
 obtaining part requirements data for the three-dimensional part;   generating a digital model of the three-dimensional part using the part requirements data, the digital model defining a shape of the three-dimensional part;   defining required structural properties of different regions of the three-dimensional part;   generating toolpath instructions for each of a plurality of layers of the three-dimensional part such that the three-dimensional part includes first and second boundary walls, defining a contour of the part, and a sinusoidal wave pattern infill structure formed between the first and second boundary walls to provide the required structural properties for the different regions of the part.   
     
     
         8 . The method of  claim 7 , wherein generating the toolpath instructions for each of the plurality of layers further comprises generating the toolpath instructions such that the sinusoidal wave pattern infill structure has a wave pattern at an orientation normal to the first and second boundary walls. 
     
     
         9 . The method of  claim 8 , wherein generating the toolpath instructions for each of the plurality of layers further comprises generating the toolpath instructions such that at least one property of the sinusoidal wave pattern infill structure is varied to provide the required structural properties for the different regions of the part. 
     
     
         10 . The method of  claim 9 , wherein the at least one property which is varied to provide the required structural properties for the different regions of the part comprises at least one of a sinusoidal wave pattern amplitude corresponding to part thickness, a beadwidth of the sinusoidal wave pattern infill structure, a frequency of the sinusoidal wave pattern infill structure, and interference of the sinusoidal wave pattern infill structure with the first and second boundary walls. 
     
     
         11 . The method of  claim 10 , wherein the at least one property which is varied to provide the required structural properties for the different regions of the part comprises the frequency of the sinusoidal wave pattern infill structure. 
     
     
         12 . The method of  claim 10 , wherein generating the toolpath instructions for each of the plurality of layers further comprises generating a predefined non-interrupted toolpath for the sinusoidal wave pattern infill structure portion of the layer. 
     
     
         13 . The method of  claim 7 , and further comprising:
 outputting the toolpath instructions for each of a plurality of layers of the three-dimensional part; and   printing the three-dimensional part using the toolpath instructions with the additive manufacturing system.   
     
     
         14 . The method of  claim 7 , wherein the three-dimensional part is an orthotic or prosthetic part for a patient, and wherein obtaining part requirements data for the three-dimensional part further comprises obtaining measured or scanned data for the patient. 
     
     
         15 . A three-dimensional part printed using an additive manufacturing technique, the three-dimensional part comprising:
 a thin-walled structure having first and second walls defining a contour of the part; and   a wave pattern infill structure formed between and in contact with the first and second walls, the wave pattern infill structure having varying properties configured to provide locally tunable structural properties in different regions of the part.   
     
     
         16 . The three-dimensional part of  claim 15 , wherein the wave pattern infill structure includes a wave pattern oriented normal to the first and second walls of the thin-walled structure. 
     
     
         17 . The three-dimensional part of  claim 16 , wherein the wave pattern infill structure has a plurality of variable properties, and wherein at least one of the plurality of variable properties of the wave pattern infill structure is varied throughout the part to locally tune structural properties in different regions of the part. 
     
     
         18 . The three-dimensional part of  claim 17 , wherein the plurality of variable properties include wave pattern amplitude, beadwidth, frequency, and interference with the first and second boundary walls. 
     
     
         19 . The three-dimensional part of  claim 18 , wherein the frequency of the wave pattern is varied throughout the part to locally tune structural properties in different regions of the part. 
     
     
         20 . The three-dimensional part of  claim 19 , wherein the wave pattern is continuous as the frequency is varied.