Utilizing Fractals for Modeling and 3D Printing of Porous Structures

Porous structures exhibiting randomly sized and distributed pores are required in biomedical applications (producing implants), materials science (developing cermet-based materials with desired properties), engineering applications (objects having controlled mass and energy transfer properties), and smart agriculture (devices for soilless cultivation). In most cases, a scaffold-based method is used to design porous structures. This approach fails to produce randomly sized and distributed pores, which is a pressing need as far as the aforementioned application areas are concerned. Thus, more effective porous structure design methods are required. This article presents how to utilize fractal geometry to model porous structures and then print them using 3D printing technology. A mathematical procedure was developed to create stochastic point clouds using the affine maps of a predefined Iterative Function Systems (IFS)-based fractal. In addition, a method is developed to modify a given IFS fractal-generated point cloud. The modification process controls the self-similarity levels of the fractal and ultimately results in a model of porous structure exhibiting randomly sized and distributed pores. The model can be transformed into a 3D Computer-Aided Design (CAD) model using voxel-based modeling or other means for digitization and 3D printing. The efficacy of the proposed method is demonstrated by transforming the Sierpinski Carpet (an IFS-based fractal) into 3D-printed porous structures with randomly sized and distributed pores. Other IFS-based fractals than the Sierpinski Carpet can be used to model and fabricate porous structures effectively. This issue remains open for further research.