3D Fabrication Layer Compensation for Shrinkage and Nozzle Defects
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Solution Overview
Problem
Conventional three-dimensional fabrication techniques face issues with discrepancies in layer thickness due to post-formation shrinkage, planar resolution incompatibility, and defective nozzle locations, leading to reduced accuracy and waste generation.
Innovation Solution
A method and system for three-dimensional fabrication that compensates for post-formation shrinkage by forming layers at predetermined thicknesses and rescaling horizontally, while also addressing defective nozzle issues by overlapping non-defective sectors with defective ones, to maintain dimensional accuracy and reduce waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If layers are formed at standard thickness using conventional three-dimensional fabrication techniques, then the fabrication process is simple and fast, but post-formation shrinkage causes discrepancies in layer thickness and reduced dimensional accuracy
Solution Approach 1:
The patent applies preliminary action by calculating and compensating for shrinkage before the actual layer formation process. The system determines expected shrinkage based on layer thickness and material properties, then adjusts the initial layer thickness accordingly so that after shrinkage occurs, the final thickness matches the target dimension. This pre-compensation approach resolves the contradiction by ensuring precision without requiring complex real-time control during fabrication.
Solution Approach 2:
The patent changes physical parameters by adjusting layer thickness as a function of material properties and shrinkage characteristics. Instead of forming all layers at a standard thickness, the system varies the initial thickness parameter based on predicted shrinkage, transforming a constant parameter approach into a variable parameter approach that accounts for material behavior and ensures dimensional accuracy.
2Manufacturing precision
If conventional fabrication techniques are used without compensation, then the process is straightforward, but defective nozzle locations create inaccuracies in layer formation
Solution Approach 1:
The patent implements feedback by using detected defective nozzle locations to adjust subsequent layer formation operations. The system identifies defective nozzles through testing or monitoring, then uses this information to modify printing patterns, skip problematic nozzles, or compensate for their failures in later layers. This feedback loop maintains manufacturing precision without requiring complete process redesign.
Solution Approach 2:
The patent applies local quality by treating different nozzle locations differently based on their operational status. Instead of using a uniform printing approach across all nozzles, the system identifies defective locations and applies localized compensation strategies, such as adjusting material deposition patterns specifically in regions affected by defective nozzles, thereby maintaining overall layer accuracy without complicating the entire manufacturing process.
3Manufacturing precision
If standard layer thickness is used without rescaling, then the fabrication process is simple, but horizontal dimensions accumulate errors due to shrinkage
Solution Approach 1:
The patent applies preliminary action by performing horizontal rescaling before layer formation begins. The system calculates cumulative shrinkage effects on horizontal dimensions and applies a rescaling transformation to the digital model or printing path accordingly. This pre-compensation ensures that as layers are formed and shrinkage occurs, the final horizontal dimensions match the target specifications without requiring complex real-time adjustments.
4Productivity
If rapid prototyping is performed using conventional techniques, then productivity is high, but material waste increases due to excessive layer thickness variations
Solution Approach 1:
The patent changes the layer thickness parameter dynamically based on position and material properties rather than using a constant thickness value. By adjusting thickness parameters to account for predicted shrinkage variations, the system ensures more consistent final layer thicknesses, reducing the need for excessive material deposition and subsequent removal, thereby decreasing material waste while maintaining rapid fabrication capabilities.
Data Source
AI summary
A method of three-dimensional fabrication of an object is disclosed. The method comprises: forming a plurality of layers in a configured pattern corresponding to the shape of the three-dimensional object, at least one layer of the plurality of layers being formed at a predetermined and different thickness selected so as to compensate for post-formation shrinkage of the layer along a vertical direction. In various exemplary embodiments of the invention spread of building material of one or more layers is diluted at least locally such as to maintain a predetermined thickness and a predetermined planar resolution for the layer.