In the realm of 3D printing, infill density is a crucial factor determining the structural integrity and material efficiency of printed parts. Traditionally, uniform infill patterns are applied throughout a model, often leading to either over-engineered, material-heavy prints or under-supported, weaker structures. Recognizing this challenge, innovators have explored methods to dynamically adjust infill density based on structural needs.
One such earlier approach, the Smart Infill method, utilized finite element simulations to identify stress concentration areas and apply mesh modifiers to increase infill precisely where needed. While effective, this method presented complexities and lacked seamless integration into standard slicing software. The desire for a more intuitive and universally applicable solution for variable infill density persisted.
Existing slicer functionalities like CURA’s gradual infill and Kisslicer’s dynamic infill represent steps in the right direction. CURA’s gradual infill primarily focuses on improving top layer quality by reducing overall infill density progressively towards the top surfaces. Kisslicer’s dynamic infill, a feature found in their premium version, allows for infill density modulation using greyscale images, offering a degree of control but perhaps not the precise, geometry-aware adaptability sought by some users.
My approach diverges slightly, drawing inspiration from recent explorations into extrusion width manipulation in 3D printing. Through experimentation, it’s been observed that the width of extruded material lines can be significantly varied, often exceeding 300% of the nozzle orifice diameter and also going below the nozzle size. This inherent flexibility in extrusion width presents an opportunity to dynamically control material flow during infill printing.