A unique characteristic of FDM® technology is that a single part can have regions
with different build styles, which can be used to make a part with variable densities. Unlike default interior styles, such as solid or sparse that are applied to the entire part, variable densities allow a single part to have combinations of solid and sparse fill styles, and each region’s density can be adjusted independently (Figures 1 and 2). With just a few minutes of extra design and pre-processing, you can save hours of build time and/or dramatically improve the part’s properties.

The advantages of variable density parts are:
• Optimized strength, weight and performance
• Reduced build time and cost
• Enable niche applications (e.g., end-use parts, fiber molding and thermoforming)

Variable density parts are created using a combination of 3D computer-aided
design (CAD) and Insight™ software. For complete control over each region, the
3D CAD model is split into sub-components and each may have a unique density.
Each subcomponent is processed with different toolpath options (Figures 3 and 4).
The use of variable density is common when optimizing a design for functionality.
For example, solid fill is used where additional strength is needed, while the
remainder of the part is built using sparse fill.

For more information, please download the full document here.

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