3D Printer Path Segmentation to Prevent Ringing at High Speed
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Solution Overview
Problem
Existing 3D printing technologies face challenges in achieving both high speed and quality due to issues like overshoots and oscillations, which result in defects such as 'ringing', especially when increasing motion parameters like speed and acceleration to save print time.
Innovation Solution
A printer and method that segment the printing path into line segments and transition segments, allowing for controlled minimum speed and maximum acceleration, ensuring the tool is only activated within safe zones to maintain quality while increasing speed, particularly applicable to low-cost additive manufacturing systems with mechanical limitations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If motion parameters (speed and acceleration) are increased to save print time, then productivity is improved, but manufacturing precision deteriorates due to overshoots and oscillations causing ringing defects
Solution Approach 1:
The printing path is segmented into multiple line segments, and transition segments are inserted between adjacent line segments. This segmentation allows the system to control motion parameters at different path sections, enabling high speed on simple segments while maintaining precision on complex segments with sharp turns.
Solution Approach 2:
Transition segments are defined in advance between adjacent line segments based on predicted motion requirements. These transition segments prepare the motion parameters (speed and acceleration) before entering critical path sections, preventing overshoots and oscillations before they occur.
2Manufacturing precision
If the tool is activated continuously to maintain material deposition, then manufacturing precision is improved, but loss of substance increases due to material deposition in non-critical areas
Solution Approach 1:
The tool activation state is controlled locally based on the specific path segment being traversed. The tool is activated only when the adding-position is within a line segment (critical deposition area) and deactivated during transition segments (non-critical areas), optimizing material usage while maintaining shape accuracy in critical regions.
3Manufacturing precision
If transition segments are defined with strict minimum speed and maximum acceleration constraints to maintain quality, then manufacturing precision is improved, but productivity deteriorates due to reduced motion efficiency
Solution Approach 1:
The motion parameters (speed and acceleration) are dynamically adjusted based on the specific characteristics of each transition segment and subsequent line segment. The controller defines transition segments with optimized minimum speed and maximum acceleration constraints tailored to each path section, balancing quality requirements with motion efficiency.
Data Source
AI summary
A printer for printing a 3D object based on a computer model, the printer comprising a tool for extruding or solidifying material, a stage supporting layers of the object; motion structure defining the shape of the layers, and a controller configured to make a path to be followed for making the object. To increase at least one of the speed and the precision by which the object is made, the controller is configured to define the path by defining a plurality of line segments and by defining transition segment for insertion between the line segments. The controller is further configured to only demand material deposition along the line segments and not along the transition segments.