Warp-free 3D printing of large-format parts

The function enables users to easily create temporary stiffening structures for parts to avoid warping, without extensive modifications to the original CAD geometry.

Long, flat and thin-walled part geometries in particular are prone to deformation in powder-based manufacturing processes. Uneven heating and cooling create thermal gradients and internal stresses can cause parts to warp.

A common approach is to add stiffening elements during the design stage, making them an integral part of the CAD model. The new Stiffener function simplifies this process by allowing users to generate temporary reinforcement directly in 4D_Additive during build preparation.

This is where the new Stiffener function in 4D_Additive comes in, enabling the easy creation of temporary stiffening structures without extensive modifications to the original CAD geometry.

The new function enables the rapid creation of temporary stiffening structures based on predefined honeycomb, triangular or quadrilateral patterns. Users can first freely define the position of the stiffening structure within the part and then generate the desired geometry. In addition to selecting the structural pattern, the dimensions of the individual cells can be defined separately and adapted to the requirements of the respective part.

The stiffening structures are connected to the CAD geometry by means of so-called pins. The geometry, position and orientation of the pins are specifically adjusted so that connections are made exclusively to the part surfaces selected by the user.

The connecting pins feature freely configurable contact points that can be easily removed from the part once it has cooled completely. The pins, which are specifically optimised for 3D printing and have a small contact area, allow subsequent processing to be kept to a minimum.

The new Stiffener function thus enables the manufacture of large-format, thin-walled parts with minimal warping, without permanently altering the original CAD design or having to undertake the time-consuming design of stiffening elements in a CAD system.

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