Vertical Brick Layers/Interlock Layers

[theboee]

Is there an existing issue for this feature request?

• I have searched the existing issues

Is your feature request related to a problem?

I am reopening this enhancement since the old one, #4133, was closed and marked stale a while back. I am doing this to try to get contributors attention and hopefully get this in the slicer. I expect this to be closed since it is a duplicate, so no hard feelings on that front.

This process results in stronger interlayer bonds and in turn increases layer adhesion in the Z plane. Initial testing by CNCKITCHEN had the improvement in strength somewhere around 10-14%, but he reveals that this is with "old wet and unreliable filament.". The true numbers could be higher when used in conjunction with good dry filament.

https://www.youtube.com/watch?v=5hGm6cubFVs

This would help all functional prints across every printer.

Which printers will be beneficial to this feature?

All

Describe the solution you'd like

There should be an option to enable "Brick Layers" or, for possible rights issues reasons, something like "Interlock Layers".

Describe alternatives you've considered

Learn how to code myself but I don't really have the time or talent so...

Additional context

No response

[buzzhuzz]

I made a change a patch which adds layer interlocking by making intersection look like brick layers (like actual brick wall with layers shifted in horizontal direction): you could read about it here #5261

I've since found and resolved a root cause of the issue which made me develop this patch (under-extrusion on acceleration), but I still always use it for all my engineering prints.

It should be possible to improve that change for merging into the code base, but I'm not sure if I would be able to fix walls finishing quality.

[theboee]

@SoftFever

[theboee]

Another thing to add, would be to increase the flow rate and line width for the offset layers to help aid adhesion.

If your material requires a 1.02 Flow Rate, than you'd tune your functional parts with Vertical Brick Layers to over extrude on the offset layers. This would get rid of the gaps that formed when CNCKitchen tested this.

So when working with this, the slicer settings could look like -

Offset Extrusion Multiplier/ 1.0 or % of existing Flow Rate

Offset Extrusion Width/ 0.4mm or % of default line width

[theboee]

I made a change a patch which adds layer interlocking by making intersection look like brick layers (like actual brick wall with layers shifted in horizontal direction): you could read about it here #5261

I've since found and resolved a root cause of the issue which made me develop this patch (under-extrusion on acceleration), but I still always use it for all my engineering prints.

It should be possible to improve that change for merging into the code base, but I'm not sure if I would be able to fix walls finishing quality.

This is also an interesting way of aiding z strength. I wonder if there may be a way of combining these methods?

[VigilantGardener]

Another thing to add, would be to increase the flow rate and line width for the offset layers to help aid adhesion.

If your material requires a 1.02 Flow Rate, than you'd tune your functional parts with Vertical Brick Layers to over extrude on the offset layers. This would get rid of the gaps that formed when CNCKitchen tested this.

So when working with this, the slicer settings could look like -

Offset Extrusion Multiplier/ 1.0 or % of existing Flow Rate

Offset Extrusion Width/ 0.4mm or % of default line width

This would be a key facet of this feature, allowing the full gap to be filled with material.

Additionally, the ability to control the part cooling fan for the offset layers. The offset layers shouldn't be part of critical part geometry, they're just about strength. The ability to alter part cooling, to include no part cooling, would mean that filament could go down hot for maximum inter-wall and inter-layer adhesion.

EDIT:
Flow rate
Cooling
Speed

Minimum available settings to leverage full value from this feature

[rkarlsba]

It seems tis is patented, but that patent is fake - it just refers to common knowledge https://www.youtube.com/watch?v=9IdNA_hWiyE

[VigilantGardener]

It seems tis is patented, but that patent is fake - it just refers to common knowledge https://www.youtube.com/watch?v=9IdNA_hWiyE

Which is a bummer, but it seems like the 1995 patent would hold sway and I think legally the feature can be implemented in any slicer now.

[kmetani]

This is great! I would love to try this on my own slicer software and 3d print using it, how can I download the necessary files to use your method of brick layering. Please note that I barely use github and can't get my way in it very well, so use easy language for the instructions on downloading it please.

[weaseljohnson]

Commenting here for visibility, and to reiterate the point that this feature is no longer patented.

https://youtu.be/9IdNA_hWiyE

[rkarlsba]

Commenting here for visibility, and to reiterate the point that this feature is no longer patented.

https://youtu.be/9IdNA_hWiyE

I posted that above ;)

[scottdky]

All three techniques should be implemented:

1. Staggered layers in z direction
2. Higher flow rate on inside perimeters
3. Stop fan on inside perimeters

By implementing all three would result in even greater bonding than the 10 to 15% from just item 1. It would be very close to isotropic.

[cgarz]

This would be so good for stuff like support material free threads.
No longer would there be such a penalty to strength 🥳🤤

I hope those patent trolls don't ruin this 😑

[robertjtaggartjr]

Yes please implement this !!!!!

[mstrblueskys]

Additionally, the ability to control the part cooling fan for the offset layers. The offset layers shouldn't be part of critical part geometry, they're just about strength. The ability to alter part cooling, to include no part cooling, would mean that filament could go down hot for maximum inter-wall and inter-layer adhesion.

EDIT: Flow rate Cooling Speed

Minimum available settings to leverage full value from this feature

The hard part about that would be inner walls are higher for half the print, so you might get seepage over the outer walls.

I wonder if the answer is not offsetting layers, but halving the inner wall layer height and printing one that's at a materially significant increase in temp without cooling to allow it to seep and then covering it up with a regular layer with normal cooling. If we're trying to increase surface area between layers, this might give us more. See my awful paint skills below. The outer layers print normal, the green layer is an hot, oozy one, and the red layer is normal again.

Maybe this would get around that awful "patent" that's out there, too.

[Sab-tech-lab]

There are another ideas on reddit:
https://www.reddit.com/r/3Dprinting/comments/1fp65o5/idea_advanced_method_of_brick_layering_for_fdm/
https://www.reddit.com/r/fosscad/comments/1grmdeg/hexagonal_brick_layers_infill/

Another good idea:
https://forum.bambulab.com/t/interlocking-layers/50505

[robingosse]

Following...

I desperately want this feature implimented in Orcaslicer. Is anyone working on it? I've been doing some research, I've read about the patent shenannigans, I've seen some clever work arounds where the printer makes a "moving centipede" shape with a single bead, I'm not sure how else to describe it, so it interlocks in 3 directions rather than 2D layers. (link here: https://www.reddit.com/r/3Dprinting/comments/1fp65o5/idea_advanced_method_of_brick_layering_for_fdm/?share_id=p-h3mZitRuujvYZZ0Kh_t&utm_content=1&utm_medium=android_app&utm_name=androidcss&utm_source=share&utm_term=1)

I just want this feature. Anyone have any recent updates?

[cgarz]

@robingosse That link is actually in the comment just before yours. Except without all the tracking stuff after the question mark which isn't needed. It can even be trimmed all the way back to the comments/1fp65o5 part.

[Anthony-Bec]

following

[tilmaen]

I posted the following in the cura github already:

I would totally love this feature.
The european Patent hasn't been awarded yet (4 years in limbo). it seems it is stuck because of a more thorough examination process. 3rd-Party observations have been filed (and acknowledged), also the examiner seemed to have found several issues of "non novelty", Also the bungled up references to the prior Patents were critizized by the EPC officer (as opposed to the USTPO).
The correspondence is pretty interesting https://register.epo.org/application?number=EP21175830&lng=en&tab=doclist
i have a friend who works there (different department) i might ask him, whether he can tell me something about that patent application.