3D Printer Build Envelope Layout Using Virtual Bounding Boxes
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Solution Overview
Problem
3D manufacturing systems face inefficiencies in arranging multiple parts within a build envelope due to the complexity of irregular shapes, leading to suboptimal use of space and increased printing time and material costs.
Innovation Solution
The use of virtual bounding boxes to simplify the arrangement of parts by generating simpler geometric shapes that can be computationally optimized for placement within the build envelope, minimizing volume and maximizing free space complexity, thereby enhancing printing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If irregular shapes of parts are directly arranged in the build envelope, then the arrangement reflects actual part geometry, but the computational complexity increases significantly
Solution Approach 1:
The patent segments the complex arrangement problem into two stages: first arranging simplified bounding boxes, then adjusting to final part positions. This segmentation reduces computational complexity while maintaining arrangement accuracy.
Solution Approach 2:
The patent introduces virtual bounding boxes as intermediary objects that simplify the arrangement computation. These bounding boxes serve as mediators between the complex part geometries and the arrangement algorithm, making the computational process more manageable.
2Productivity
If more parts are arranged in the build envelope, then the space utilization improves, but the printing time increases
Solution Approach 1:
The patent employs dynamic adjustment of part arrangements based on build height minimization. The system dynamically optimizes the configuration to fit more parts while controlling the build height, thereby balancing space utilization with printing time.
Solution Approach 2:
The patent changes the optimization parameter from simple volume packing to height-minimized packing. By optimizing for minimum build height rather than maximum volume utilization, the system reduces printing time while still achieving high space utilization.
3Loss of time
If parts are arranged to minimize build height, then the printing time is reduced, but the thermal coupling between parts increases
Solution Approach 1:
The patent applies local quality adjustment by introducing thermal gaps specifically between parts that would otherwise be in thermal contact. While the overall arrangement minimizes build height for reduced printing time, local modifications ensure thermal isolation where needed.
Solution Approach 2:
The patent performs preliminary identification of potential thermal coupling issues during the arrangement phase and preemptively introduces gaps or adjustments to prevent thermal interference before printing begins.
Data Source
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AI summary
According to an example, an arrangement of parts to be printed in a build envelope of a three dimensional (3D) printer may be determined through identification of a plurality of parts to be printed and generation of a respective virtual bounding box for each of the plurality of parts. In one example, a determination may be made that a total volume occupied by the generated virtual bounding boxes falls below a predetermined threshold of the build envelope volume and an arrangement of the virtual bounding boxes inside the build envelope that results in a total height of the virtual bounding boxes being minimized may be determined, to enhance efficiency in printing of the plurality of parts by the 3D printer.