3D Deposition Path Planning for Selective Gap Filling

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Solution Overview

Problem

Existing three-dimensional shaped object manufacturing methods often extend processing time by filling void regions that do not need to be filled, such as negligibly small gaps, which can be inefficient and unnecessary.

Innovation Solution

A method that generates intermediate data to increase the amount of shaping material deposited along paths and specifies gap regions between deposition areas, allowing the shaping material to be deposited in these regions, thereby reducing the number or area of unnecessary gaps and optimizing the shaping process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the remnant path is used to fill all void regions, then the void ratio in the three-dimensional shaped object is reduced, but the processing time is extended due to filling unnecessary gaps

Engineering Contradiction:
Improvevoid ratioVSAvoidprocessing time
Core Design Contradiction:
Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent applies local quality by differentiating between necessary void regions and unnecessary gap regions. The system calculates the void ratio and identifies specific gap regions that do not contribute to structural integrity. By selectively filling only necessary voids while leaving unnecessary gaps unfilled, the patent optimizes the local deposition characteristics to achieve the desired overall void ratio without wasting time on redundant filling operations.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent implements partial action by determining that complete filling of all void regions is excessive. Instead, it calculates the minimum necessary filling to achieve the target void ratio and stops there. The system identifies gap regions that can be left unfilled without compromising the structural requirements, thus performing only the necessary portion of the filling operation rather than an excessive complete fill of all voids.

Inventive Principle:
Principle #16Partial or excessive action

2Manufacturing precision

If the discharge amount is increased to fill gap regions, then the void ratio is reduced, but the amount of shaping material consumed increases

Engineering Contradiction:
Improvevoid ratioVSAvoidshaping material
Core Design Contradiction:
Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent applies local quality by varying the discharge amount based on the specific characteristics of each region. For necessary void regions, the discharge amount is increased to ensure proper filling. For unnecessary gap regions, the discharge amount is reduced or set to zero, avoiding wasteful material deposition. This localized control of material discharge optimizes both void ratio achievement and material efficiency.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent implements partial action by determining the minimum necessary material deposition to achieve the target void ratio. Instead of uniformly increasing discharge across all regions (which would be excessive), the system selectively increases discharge only where necessary to fill critical voids, leaving unnecessary gaps unfilled. This partial deposition strategy achieves the desired void ratio while minimizing material consumption.

Inventive Principle:
Principle #16Partial or excessive action

Data Source

PatentUS11623410B2Three-dimensional shaped object manufacturing method and information processing device
Publication Date: 2023.04.11 SEIKO EPSON CORP
  • US11623410B2 patent drawing
  • US11623410B2 patent drawing
  • US11623410B2 patent drawing

AI summary

A three-dimensional shaped object manufacturing method includes a first step of acquiring shape data corresponding to a three-dimensional shaped object, a second step of generating, using the shape data, first intermediate data including path information indicating a path along which a depositing unit moves while depositing a shaping material and depositing amount information indicating a depositing amount of the shaping material, a third step of generating second intermediate data by changing the first intermediate data to increase an amount of the shaping material deposited and specifying a gap region interposed between regions where the shaping material is deposited according to the second intermediate data, a fourth step of generating shaping data by changing the first intermediate data or the second intermediate data such that the shaping material is deposited in the specified gap region, and a fifth step of shaping the three-dimensional shaped object according to the shaping data.