3D Print Orientation Selection for Surface Finish and Accuracy

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Solution Overview

Problem

In additive manufacturing, controlling the appearance, mechanical, and accuracy characteristics of three-dimensional objects is challenging, particularly in preventing issues like capillaries, sinks, surface finish, stair stepping, dimensional inaccuracies, and mechanical property variations.

Innovation Solution

An automated system that uses a computing apparatus with a processor and memory to determine optimal manufacturing orientations and positions for three-dimensional objects based on desired characteristics, employing machine learning systems and data processing systems to standardize input data and prioritize object characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If automated orientation selection is implemented, then manufacturing precision and appearance quality are improved, but device complexity increases

Engineering Contradiction:
Improvedimensional accuracyVSAvoidsystem complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system enables self-service by allowing the additive manufacturing system to automatically determine optimal build orientations and positions using machine learning models, eliminating the need for skilled operators to manually configure these parameters. The system serves itself by autonomously selecting orientations that prevent defects like capillaries and sinks, thereby improving manufacturing precision without requiring additional human expertise or intervention.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The system applies preliminary action by pre-training machine learning models with extensive manufacturing data and defect patterns before actual production. The models are prepared in advance to automatically evaluate and select optimal build orientations, preventing quality issues before they occur during the manufacturing process. This preliminary preparation enables the system to make informed decisions without real-time human intervention.

Inventive Principle:
Principle #10Preliminary action

2Ease of operation

If automated orientation determination is used, then ease of operation is improved, but manufacturing precision may be compromised

Engineering Contradiction:
Improveoperator skill requirementVSAvoidsurface finish quality
Core Design Contradiction:
Ease of operationVSManufacturing precision

Solution Approach 1:

The system achieves self-service by empowering non-skilled operators to achieve high-quality results through automated orientation selection. The machine learning models handle the complex decision-making regarding build orientations, allowing anyone to operate the system without specialized knowledge while maintaining consistent quality standards. The system effectively does the expert work itself, making operation easy for anyone.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The system implements feedback by using trained machine learning models that have learned from historical manufacturing data and defect patterns. The models continuously evaluate potential build orientations against known quality criteria and defect prevention rules, providing feedback-driven recommendations that ensure surface finish quality and dimensional accuracy are maintained even when operated by non-experts.

Inventive Principle:
Principle #23Feedback

3Manufacturing precision

If multiple object characteristics are considered, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:
Improveappearance characteristicsVSAvoiddata processing complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system merges multiple evaluation criteria including appearance characteristics, mechanical properties, and dimensional accuracy into a single integrated machine learning model. The model simultaneously considers all these factors when determining optimal build orientations, consolidating what would otherwise require separate analysis systems into one unified decision-making framework. This merging reduces the operational complexity while maintaining comprehensive quality control.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The system applies parameter changes by transforming multiple quality parameters (surface finish, dimensional accuracy, mechanical strength) into a standardized evaluation framework that the machine learning model can process. The model evaluates different build orientations based on how they affect various parameters, and automatically selects the orientation that optimizes the overall quality profile across all considered characteristics.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS12220869B2Object orientation and/or position for additive manufacturing
Publication Date: 2025.02.11 PERIDOT PRINT LLC
  • US12220869B2 patent drawing
  • US12220869B2 patent drawing
  • US12220869B2 patent drawing

AI summary

A non-transitory machine-readable storage medium storing instructions executable by a processor described. In some examples, the instructions cause the processor to receive object data representing an object to be manufactured by an additive manufacturing process. A derivation process on the object data to derive a data set representing the object, the data set having a predetermined number of data fields. The data set is provided to data processing system comprising data based on previously determined manufacturing orientations and/or position. An output is received from the data processing system representing a manufacturing orientation and/or manufacturing position of the object.