3D printing and filling: how to choose the best parameters

The correct choice of infill pattern for 3D printed parts can make a huge difference: we discuss about this with our CTO Davide Ardizzoia, involving?SSI 2023?software, a perfect ally in infill management process.

Additive manufacturing has opened the door to flexible, rapid and innovative manufacturing, from single part to medium-sized batches.

If we get into the merits of 3D printed parts, each can be considered as the sum of two distinct elements: outer geometry and inner filling.

While the exterior is generally imposed by the aesthetic and functional synthesis of the design, other kinds of evaluations take over on the interior. Indeed, among the features to be considered are density and fill pattern, which will affect the mechanical performance and weight of the finished product.

Depending on internal density, parts molded with?Fused Filament Fabrication?(FFF) systems can offer different strength, weight and elasticity options. Parts with purely aesthetic value (filling up to 15%), with good strength (up to 75%) or for extreme uses (100%) can be made.

But let's talk about geometries

The geometry chosen for the fill is also an important parameter, as it determines its eventual fillability (e.g., with resins or ceramics) or isotropy (to be considered according to type and direction of the stresses they have to withstand).

To date, evaluation has been dictated by the experience of operators who, to avoid potential problems, tend to limit themselves to oversizing the printing parameters. However, this results in higher material usage and longer printing times: in both cases, there is an unacceptable waste of resources.

How then to choose among the many variables available??

To answer this need, we at 3ntr are performing a series of instrumental tests useful for obtaining all the information to establish the most suitable parameters according to the design requirements.

To date, linear, octagonal, cellular, gyroid, triangular and hexagonal infill geometries are used, but even constant spanning is showing its limits. Here then, to meet new technical demands in a dynamic and progressive manner, adaptive solutions are emerging.

Whatever the designer's choice,?SSI 2023 software?can easily handle each of these criteria and maximize printer productivity while reducing operating costs.

As future releases are released, the options available will also increase further, and the software will be enriched with the experiences gained by 3ntr's research and development department.

Users of 3ntr systems will thus be able to obtain high-performance parts by performing fewer interactions and thus using only the material actually needed. This, combined with the availability of preloaded printing profiles, already enables users to always use the best parameters without wasting material or energy.

A great added value from an economic point of view, but also in terms of environmental sustainability.