Brick Layers - Why did no one do this before?

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3D prints still suffer from bad layer adhesion due to their 2.5D slicing and printing approach. I investigated if a novel slicing method that interleaves the layer could improve the strength of 3D prints.

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📚 Printed Models:

*Chapters*
00:00 Introduction
01:47 Brick Layers
04:20 Implementation in Simplify3D
04:55 Print Quality
05:55 Strength Tests
08:51 Summary
09:33 Sponsor
10:55 Outro

#3Dprinting #Slicing #Future
DISCLAIMER: Part of this video was sponsored by Brilliant.
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We own a print farm and run hundreds of prints in PETG that are subject to high daily stress loads. We found that larger nozzles with slight over-extrusion increasing the XY plane contact between rows along with optimal temp gave us the highest strength. There is an upper limit though, forcing us to design based on the print direction. Stefan, I’ll have to run some torture test samples at the larger nozzle diameter to see if it’s worth implementing for our prints. Thanks for the info!

lightsnsiren
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Coming from concrete strength testing, you want the test cylinder to explode under compression. If just a part snaps off, or it cracks just by one cleavage point than the test cylinder is not homogeneous. Similar to how your parts exploded it likely means more parts of your model were experiencing stress at the same time tell the plastic itself had to give. For ridged materials optimal strength testing often ends with an explosion.

connorerb
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let's hope this goes viral and the big slicers start implementing stuff like this

laszlom.
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A 10% increase in strength with negligible changes in print times sounds pretty good. Seems like prints using this method may be more water tight as well. We need definitely need more testing. Great video!

ethansdadd
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I'm a bricklayer. Problem here is your stacking your "bricks" again, just on a different plane. Real bricks on running bond sit so each brick sits equally above two other bricks. The point of this is to divide the weight of the wall equally down, so the compressive load is much greater. Shear strength is not it's specialty. Your thumbnail image would be more correct if you rotated it 90⁰. In the thumbnail all I see is four stacked columns. But that would only be for compressive strength, which is all real bricks do.

Pizzapleaze
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I tested this method last Auguest for my Master's degree. I implemented it in PrusaSlicer with some CAD trickery. In addition to the things tested in the video I also tested a parameter that I call overlap. Overlap is the amount that the adjascent extrusion lines intersect with each other. resulting in a more solid part. My results showed that at higher overlap this new approach had no advantage over traditional printing (where higher overlap can be achieved my simply extruding more). The max interlayer strength I acheived was ~35-36Mpa in PLA for both printing methods, but the interlocking layers were printed slower because of double the amount of layer changes.

mw
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The crack features on the brick printed parts strongly implies increased vertical and horizontal bonding, leading to increased homogeneity, which is why the failures were 3d and not 2d. The 45 degree oriented bonding in the brick prints is notable in this regard.

mausball
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This is indeed a low-cost but effective improvement plan. Thank you for promoting this idea!

eeuse
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I don't know how this video ended up on my dash given that I don't own a 3D printer, but I still want to acknowledge your craft. This was both eloquently and succinctly explained, your theory and tests show a strong grasp of the underlying physics, the graphics are clear and informative, and whenever you presented data you did so in a clear and complete manner. Content entirely aside as I don't care about the topic, I still stuck around to relax in the presence of charts with titles, honest axes, and even error bars. Thank you!

TheAramil
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3:03 There is a 2020, patent but it's a copy of a 1995, patent which had expired so this process is public domain now despite the 2020 patent which should easily be challenged in court.

TheRecord
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This is amazing!!! This is the exact reason I watch this channel. Not only to learn how to 3d print but to better the process of 3d printing. I'm not an engineer but was always fascinated by how things were made and how to make something better. This is exactly what this channel offers. Thanks you Stefan!!!

phillipremondini
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"Simplify3D" That's a name I haven't heard in a long, long time

JLaFs
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I actually submitted this as an idea for Bambu Studio/Orca Slicer almost a year ago. It is nice to see it in action. My use case was to make thin walled parts, such as a simple bin/cup stronger by using the offset layers. Imagine a part with a wall three lines thick. Now offset the middle line in the wall, as you have demonstrated. There is no longer a single layer line cutting through the wall. line

juliejones
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This exists in Cura.. partially. Set infill layer height higher/lower than regular height. Select extra infill wall count. Also increase the outer/inner wall overlap. You should get at least 3 walls overlapping. That's the limitation as far as I know.. but most people dont print with more than 3 walls.

injesusname
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I print only in high strength filament. I don't bother with ABS or PETG, etc. That your brick laid model exploded (rather than cleanly detach from a layer) is ample proof that you have achieved injection level strength. A 10 to 14 percent increase in strength is very significant in functional parts. Great work Stefan!

rexsolomon
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Increasing extrusion temp and enclosing the printer might create a more bonded structure using this pattern. Really great work!

HippyEngineer
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Great idea. If combined with the techniques you described in your video about 3D printing clear "glass" (slower, hotter), I think you'll basically fill the voids between lines and the part would be very strong.

naasking
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This channel consistently produces some of the best 3d printing content on the whole platform. Not just in form but in function as well, advancing the community farther and farther with ever video!

adamrosenhamer
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Geek Detour made a video about a patent that you were searching.

srilemobitelsrile
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I can't believe I haven't seen this tried before. It feels extremely obvious in hindsight, especially after seeing how fdm prints tend to split.

Thanks for the great work as always, Stefan!

kimirikscreations