3D Print Slice Definition for Boundary Fusing Control
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Solution Overview
Problem
Additive manufacturing processes often result in unintended fusing around the boundary of objects due to thermal conduction from fused areas, leading to excess fusing outside the intended 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
Engineering Contradiction Analysis
1Manufacturing precision
If energy is applied to cause melting and fusing of build material, then the object structure is formed, but unintended fusing occurs around the boundary due to thermal conduction
Solution Approach 1:
The patent applies preliminary anti-action by depositing a fusing reduction agent in regions surrounding the intended fusing boundaries before the melting and fusing process occurs. This agent creates a thermal barrier that preemptively counteracts the thermal conduction that would otherwise cause unintended fusing, thereby preventing the harmful effect before it can manifest.
Solution Approach 2:
The fusing reduction agent serves as an intermediary substance between the energy source and the build material boundary regions. This intermediary absorbs or redirects thermal energy, mediating the heat transfer process to prevent excessive thermal conduction into areas where fusing should not occur, thus resolving the contradiction between achieving sufficient fusing and preventing excess fusing.
2Strength
If thermal energy is conducted to fuse build material, then material bonding is achieved, but heat transfer causes unintended fusion outside boundaries
Solution Approach 1:
The patent implements local quality by applying the fusing reduction agent selectively in specific regions around the boundaries of the object to be formed. This creates localized thermal barrier properties only where needed at the boundaries, while the interior regions maintain full thermal conductivity for proper material bonding. This localized application preserves material bonding strength while preventing boundary definition errors.
Solution Approach 2:
The patent segments the thermal management approach by dividing the build area into distinct zones: regions where fusing should occur (interior), regions where fusing should be reduced (boundary areas), and regions where no fusing occurs (exterior). The fusing reduction agent is applied specifically to the boundary zones, segmenting the thermal field to simultaneously achieve material bonding in interior regions and boundary precision in boundary regions.
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 while optimizing for strength, accuracy, and resource efficiency.
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.
Implementation Method 2
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.
Implementation Method 3
additive manufacturing processes which apply heat to build material in order to cause selective fusing may result in unintended fusing outside a boundary of an object owing to thermal conduction from a fused area
Data Source
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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 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.