Application of 3D printing DLP technology in cushion industry

DLP printers use DMD (Digital Micro Projection Chip), which is composed of millions of tiny reflectors. Each reflector can be controlled independently and can be tilted to adjust the direction of light projection. The number of mirrors within the DMD determines the printing resolution.

The principle of DLP 3D printing technology is based on the properties of light-curing resin. Before printing begins, DLP cuts the 3D model into many thin layers based on its data. When the printer works, it projects an image onto the photosensitive resin. The image is made up of millions of tiny points of light, each corresponding to a pixel. These tiny spots of light influence the resin, causing it to solidify into the desired shape. Then, the printing platform gradually rises, and printing is repeated layer by layer until the entire model is completed.

Elastomer 3D printing, also known as flexible 3D printing, has the advantages of being lightweight, customizable, having excellent temperature resistance, durability, etc., and having fewer design restrictions.
1. Lattice shape adjustment
By adjusting the lattice shape, different mechanical properties and different appearances can be obtained.
There are tens of thousands of lattice shapes. Qingfeng passed “many tests” and only left 16 high-quality lattice shapes on the LuxStudio lattice platform.
They can be classified into regular rod diameters, minimal surfaces, and Thiessen polygons, and different shapes have different mechanical properties and can form different appearances.
2. Rod diameter adjustment
Adjusting the diameter of the lattice rods can change the strength and toughness of the lattice structure.

For example, if the diameter of the lattice rod of a 3D-printed bicycle seat is adjusted, the hardness of the lattice will change accordingly. The structure of the thin rod diameter is relatively soft, and the hardness increases with the thick rod diameter.

This kind of 3D-printed bicycle seat cushion made from flexibility can provide support to the seat bones and achieve reasonable pressure distribution. At the same time, it does not affect the mechanical effect of the structure itself. It also increases natural breathability and improves the riding experience.
3. Lattice size adjustment
Adjust the lattice size to complete a lightweight design and meet printing needs without affecting the volume ratio.

For example, for a 3D-printed cervical pillow that requires a soft and resilient state, the diameter of the lattice rods under normal design is too thin to meet the printing requirements. If the lattice size is proportionally expanded and widened, the weight of the cervical pillow will become lighter, but the performance will not be affected while meeting printing needs.