3D Print Orientation Using Overhang Volume Minimization

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Solution Overview

Problem

Current 3D printing technologies face challenges in optimizing the orientation of objects during the printing process, leading to increased overhang volumes that require additional material for support, resulting in material waste and potential defects due to material bending during solidification.

Innovation Solution

A computer-implemented method determines optimal orientations for 3D printing based on minimizing overhang volume, allowing for reduced support material usage and improved print quality by calculating and identifying orientations that minimize overhang volume through discrete optimization techniques and geometric computations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If 3D printing is performed with default or arbitrary orientations, then the printing process can be completed, but overhang volume increases requiring additional support material and causing potential defects

Engineering Contradiction:

Improvematerial consumptionVSAvoidprint quality

Core Design Contradiction:

Loss of substanceVSManufacturing precision

Solution Approach 1:

The system performs preliminary orientation optimization by computing the overhang volume for multiple discrete orientations before the actual 3D printing process begins. The orientation with minimal overhang volume is selected in advance, preventing material waste and quality issues before they occur during printing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system changes the orientation parameter of the 3D modeled object by computing overhang volumes for different discrete orientations and selecting the optimal orientation that minimizes overhang volume, thereby reducing material consumption and improving print quality.

Inventive Principle:

Principle #35Parameter changes

2Loss of substance

If optimal orientation is determined through comprehensive computation, then material consumption and support structure complexity are reduced, but computational time and processing complexity increase

Engineering Contradiction:

Improvematerial consumptionVSAvoidcomputational time

Core Design Contradiction:

Loss of substanceVSLoss of time

Solution Approach 1:

The system computes overhang volumes for a finite discrete set of orientations rather than all possible continuous orientations. This partial action approach provides sufficiently optimal results while significantly reducing computational time and complexity compared to exhaustive search.

Inventive Principle:

Principle #16Partial or excessive action

3Ease of manufacture

If support structures are added for overhang surfaces, then printing feasibility is improved, but the complexity of support structure design and material usage increase

Engineering Contradiction:

Improveprinting feasibilityVSAvoidsupport structure design

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The system performs preliminary orientation optimization to minimize overhang volume before printing, which reduces the extent of support structures needed. This preliminary action simplifies subsequent support structure design and reduces material usage while maintaining printing feasibility.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP4008526A1Orientation of a real object for 3D printing

Publication Date: 2022.06.08 DASSAULT SYSTEMES SA

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AI summary

The invention notably relates to a computer-implemented method for orienting 3D printing of a real object. The method comprises providing (S10) a 3D modeled object that represents the real object. The method also comprises determining (S40, S56) one or more orientations of the 3D modeled object for which an overhang volume is optimal. This improves 3D printing.