3D Print Object Nesting by Height Grouping
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Solution Overview
Problem
Existing 3D printing methods often result in inconsistent color, height deviations, and surface cracking due to overcuring of lower objects when printing objects of varying heights, as the print head's curing action affects both higher and lower objects during scanning movements.
Innovation Solution
Grouping objects by similar heights and arranging them in separate shelves to minimize overcuring, where the print head's scanning movements are confined to the area of higher objects, allowing for proper curing intensity and reducing the distance of travel, thus improving print quality and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If objects of varying heights are printed together on the same print surface, then the print surface area is utilized efficiently, but overcuring occurs on lower objects causing color inconsistency, height deviations, and surface cracking
Solution Approach 1:
The print surface is segmented into multiple shelves (first shelf, second shelf, etc.) arranged in the sub-scanning direction. Objects are assigned to different shelves based on their height characteristics, with higher objects placed on lower shelves and lower objects on upper shelves. This segmentation prevents the print head from repeatedly curing already-cured lower objects while printing higher objects, thereby eliminating overcuring issues while maintaining efficient surface area utilization.
2Productivity
If the print head scans the entire print surface to print higher objects, then all objects can be printed in sequence, but the curing intensity on lower objects becomes excessive
Solution Approach 1:
The invention applies local quality by differentiating the curing requirements for different objects based on their height. The print head is configured to apply different curing intensities or curing strategies depending on the shelf and object being printed. Specifically, when printing higher objects on lower shelves, the curing parameters are adjusted to avoid excessive curing of lower objects on upper shelves, thereby maintaining appropriate curing intensity for each local region.
3Manufacturing precision
If objects are grouped by height and printed in separate shelves, then overcuring is reduced and print quality improves, but the print head travel distance increases
Solution Approach 1:
The invention introduces a new dimension for organizing objects - the shelf dimension in the sub-scanning direction. Instead of arranging objects solely based on their 2D footprint on the print surface, objects are arranged in 3D space considering both their horizontal position and vertical shelf assignment. This dimensional reorganization allows the print head to systematically traverse shelves from lower to upper levels, reducing redundant travel and optimizing the printing path while maintaining the benefits of height-based grouping.
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 significantly reduces overcuring of lower objects, enhancing print quality by ensuring consistent curing and allowing for more efficient printing processes, including the ability to package lower objects before completing higher ones without interfering with the print head.
Implementation Method 1
A newly applied ink layer is cured, e.g. by irradiating it with UV light, so that the newly applied ink becomes solid before the next ink layer is printed
Data Source
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AI summary
Method of nesting three-dimensional print objects on a print surface of a printer, wherein the locations for the print objects on the print surface are determined so as to minimize the surface area required for accommodating the objects, and wherein the locations for the print objects are determined also in view of intended heights of the objects, and objects with equal or similar height are grouped together, the method comprising grouping the objects into classes of objects with similar heights, and nesting the objects class by class, wherein the method is performed on a printer having a print head movable relative to the print surface in a main scanning direction and sub-scanning direction, and wherein the objects of each class are nested in a separate shelf that extends in the main scanning direction on the print surface and has a constant width in the sub-scanning direction.