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I started thinking about the layer to layer adhesion issues. It seems to me there is a significant lack of strength between layers. I have seen issues on enclosures where the part will break at some weak layer. So I thought why not weave the layers?

How would that work? Well lets say you use a square wave, triangle, or sine wave pattern on one layer in the x/y axis. Then follow that up with an out of phase pattern for the next layer also in the x/y axis. However, the next layer "dips" on the peak of the out of phase pattern causing a mechanical dip down into the previous layer. It could even be setup to extrude sightly more material on the dip. This would cause not only a layer to adhere in a parallel direction, but also in a perpendicular direction of the 2 layers. Kind of like mini rivets with epoxy on the sides.

The math might be somewhat complex and I would probably really only use it for straight line runs. Like on exposed surfaces like perimeters. The finer the layer pitch the stronger it would be as well.

Very interesting idea. It would have to be implemented into the slicing tool after the math is worked out. https://github.com/alexrj/Slic3r

Demolishun wrote:I started thinking about the layer to layer adhesion issues. It seems to me there is a significant lack of strength between layers. I have seen issues on enclosures where the part will break at some weak layer. So I thought why not weave the layers?

How would that work? Well lets say you use a square wave, triangle, or sine wave pattern on one layer in the x/y axis. Then follow that up with an out of phase pattern for the next layer also in the x/y axis. However, the next layer "dips" on the peak of the out of phase pattern causing a mechanical dip down into the previous layer. It could even be setup to extrude sightly more material on the dip. This would cause not only a layer to adhere in a parallel direction, but also in a perpendicular direction of the 2 layers. Kind of like mini rivets with epoxy on the sides.

The math might be somewhat complex and I would probably really only use it for straight line runs. Like on exposed surfaces like perimeters. The finer the layer pitch the stronger it would be as well.

I'm not FULLY up to speed with Slic3r yet, but I seem to remember that there is a least ONE slicing program that offers an in-fill that is essentially a "weave".
Maybe not slic3r... I don't remember.

I don't get it...

My mind cannot imagine how is it possible to weave layers, all math apart.

Actually, even with a thread and a needle, I can't imagine a 3D weave.

However, my poor english led me to believe in the begining that you intended to do a wave.

Fluctuating in height on a sine pattern would bring more bonding surface between layers, and would make the parts stronger to shearing.

Isn't the "real" problem delamination ?
If so then I think it would be better to approach it as a "failure to properly melt into the previous layer" than as a weakness of the printing pattern.

From what little I know delamination is caused by not getting back to an area with the next layer until the previous layer has already cooled too much.
I can think of any number of potential solutions to this; Speed & area per layer being the most obvious ones, but design of the part being printed is the most likely source of the problem.

"Weaving" requires you get underneath a previously printed layer, thus it wouldn't be possible.