3D Print Slice Definition for Boundary Fusing Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Additive manufacturing processes often result in unintended fusing around the boundaries of objects due to thermal conduction from fused areas, leading to excess fusing outside the intended object boundaries.

Innovation Solution

The implementation of a print definition procedure that defines fusing reduction regions to inhibit excess fusing by using a fusing reduction agent or omitting the fusing agent in specific regions, thereby controlling heat transfer and preventing unwanted fusion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If energy is applied to cause melting and fusing of build material, then the object is formed through solidification, but unintended fusing occurs around the boundary of the object due to thermal conduction

Engineering Contradiction:

Improveboundary accuracyVSAvoidunintended fusing

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent applies a fusing reduction agent in the region outside the object boundary where thermal conduction causes unintended fusing. This agent reduces the fusing tendency of the build material, converting the harmful thermal conduction effect into a controlled process by selectively inhibiting fusing only in the boundary region, thereby preventing excess fusing while allowing normal fusing inside the object.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent introduces a fusing reduction agent specifically in the region outside the object boundary, creating a localized zone with different fusing properties. This local modification of material characteristics allows the build material to have reduced fusing tendency only at the boundary area, while maintaining normal fusing properties inside the object, thus resolving the boundary accuracy issue without affecting overall object formation.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If a fusing reduction agent is applied to inhibit excess fusing, then boundary accuracy is improved, but the process complexity increases

Engineering Contradiction:

Improveboundary definitionVSAvoidprint definition procedure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent defines a fusing reduction region in advance based on the object boundary before the actual fusing process. By pre-calculating and marking the region outside the object boundary where the fusing reduction agent should be applied, the system prepares the control strategy beforehand, simplifying the real-time decision-making process and integrating the complexity into the initial print definition procedure rather than during execution.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach effectively reduces excess fusing outside the object boundaries, maintaining the integrity of the object's structure and preventing thermal conduction, thus enhancing the accuracy and strength of the manufactured objects.

Implementation Method 1

The fusing agent may be capable of absorbing radiation (radiant heat energy) and transferring thermal energy to build material in contact with the fusing agent.

Methodology Applied

Scientific EffectAbsorption (EM radiation): Absorption (EM radiation)

Implementation Method 2

transferring thermal energy to build material in contact with the fusing agent

Methodology Applied

Scientific EffectThermal energy transfer: Conduction (thermal)

Implementation Method 3

unintended fusing outside a boundary of an object owing to thermal conduction from a fused area

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11220061B23D print definition procedures

Publication Date: 2022.01.11 PERIDOT PRINT LLC

AI summary

There is disclosed a non-transitory machine readable storage medium encoded with instructions executable by a processor and comprising instructions to: receive object data corresponding to a three-dimensional object to be generated; define print data for each of a plurality of slices of the object to control a respective layer forming operation in which print agent is ejected on a layer of build material in a pattern corresponding to selective fusing of the build material, wherein the print data and the respective pattern is defined for each slice according to object a print definition procedure; and select the print definition procedure from a plurality of print definition procedures based on a user input. There is also disclosed a corresponding method and additive manufacturing apparatus.