Design of Complexly Graded Structures inside Three-Dimensional Surface Models by Assigning Volumetric Structures

An innovative approach for designing complex structures from STL-datasets based on novel software for assigning volumetric data to surface models is reported. The software allows realizing unique complex structures using additive manufacturing technologies. Geometric data as obtained from imaging methods, computer-aided design, or reverse engineering that exist only in the form of surface data are converted into volumetric elements (voxels). Arbitrary machine data can be assigned to each voxel and thereby enable implementing different materials, material morphologies, colors, porosities, etc. within given geometries. The software features an easy-to-use graphical user interface and allows simple implementation of machine data libraries. To highlight the potential of the modular designed software, an extrusion-based process as well as a two-tier additive manufacturing approach for short fibers and binder process are combined to generate three-dimensional components with complex grading on the material and structural level from STL files.