3D Print Model Scaling for Shrinkage Compensation
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Solution Overview
Problem
Three-dimensional printed objects suffer from shrinkage during the cooling process, leading to discrepancies between the final printed size and the intended dimensions specified by the object model data.
Innovation Solution
A method and apparatus that apply compensation factors to the object model data to account for shrinkage, scaling the data with reference to the center of the printer's usable build volume to ensure accurate printing dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If object model data is printed directly without compensation, then the printing process is simple and fast, but the final printed dimensions deviate from the intended dimensions due to shrinkage
Solution Approach 1:
The patent applies preliminary action by pre-calculating and applying compensation factors to the object model data before printing. The system determines shrinkage compensation factors based on the build volume and object dimensions, then scales the model data accordingly in advance. This preliminary scaling ensures that after shrinkage occurs during printing, the final dimensions match the intended dimensions, resolving the dimensional accuracy issue without adding complex real-time adjustments.
Solution Approach 2:
The patent utilizes parameter changes by modifying the scale parameters of the object model data based on calculated compensation factors. The system adjusts the dimensional parameters of the digital model before printing, transforming the original dimensions into compensated dimensions that account for anticipated shrinkage. This parameter transformation ensures accurate final dimensions while maintaining a relatively simple printing process.
2Productivity
If multiple objects are printed in a build volume, then productivity increases, but shrinkage compensation becomes more complex and may cause collisions between objects
Solution Approach 1:
The patent applies local quality by calculating and applying individual compensation factors to each object based on its specific dimensions and position within the build volume. Rather than using a uniform compensation approach, the system determines object-specific scaling factors that account for local variations in shrinkage behavior. This localized compensation ensures each object maintains its intended dimensions and position, preventing collisions while maximizing the number of objects that can be printed simultaneously.
Solution Approach 2:
The patent utilizes segmentation by treating each object in the build volume as an independent entity for compensation calculations. The system divides the overall printing task into individual object compensations, calculating scaling factors separately for each object based on its dimensions and position. This segmented approach allows precise control over each object's final dimensions and placement, ensuring no collisions occur while maintaining high productivity through multi-object printing.
3Manufacturing precision
If compensation factors are applied to object model data, then dimensional accuracy improves, but the data processing time increases
Solution Approach 1:
The patent replaces complex iterative mechanical adjustment systems with a straightforward mathematical calculation system. Instead of using trial-and-error physical adjustments or complex simulation-based optimization, the system employs direct mathematical formulas to calculate compensation factors based on build volume and object dimensions. This substitution of mathematical computation for mechanical iteration significantly reduces data processing time while maintaining high dimensional accuracy.
Solution Approach 2:
The patent efficiently handles parameter changes by using direct scaling calculations rather than iterative optimization. The compensation factors are computed through simple mathematical relationships between build volume parameters and object dimensions, allowing rapid determination of scaled dimensions. This approach minimizes computational overhead and data processing time while achieving the desired dimensional accuracy in the printed objects.
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
Ensures that the printed objects match the intended dimensions by compensating for shrinkage, preventing collisions and optimizing print quality within the build volume.
Implementation Method 1
Energy may be applied to the layer and the build material on which an agent has been applied may coalesce and solidify upon cooling
Implementation Method 2
Three-dimensional printed objects suffer from shrinkage during the cooling process
Data Source
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AI summary
A method comprises receiving object model data in an original coordinate system to print within a predefined usable build volume of a three dimensional printer. The method comprises receiving at least one compensation factor for the object model data to compensate for any shrinking of an object. The method comprises scaling the object model data by the at least one compensation factor to provide printable object model data. The scaling is performed with reference to an origin at a centre of the usable build volume.