3D Printing Controller Energy Management for Empty Layers

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Solution Overview

Problem

3D printing systems face inefficiencies in transitioning from prototyping to high-productivity environments due to sensitivity to thermal imbalances and high thermal inertia, limiting their ability to produce larger quantities of objects efficiently.

Innovation Solution

Implementing a method that differentiates processing modes based on the presence of empty layers in the build model, adjusting operational parameters such as fusing energy application and build platform movement to optimize energy use and reduce processing time, including the use of distinct operating modes for varying numbers of consecutive empty layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional 3D printing systems operate with standard thermal processing for all layers, then temperature uniformity is maintained, but energy consumption increases and processing speed decreases

Engineering Contradiction:

Improveprocessing speedVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent segments the processing of layers into different categories: empty layers and non-empty layers. By identifying and separately processing empty layers (which require minimal or no fusing energy) versus non-empty layers (which require full thermal processing), the system reduces overall energy consumption while maintaining temperature uniformity through selective application of heating processes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system dynamically adjusts fusing energy application based on real-time detection of empty layers. The controller modifies processing parameters mid-build, reducing or eliminating fusing energy for detected empty layers while maintaining standard processing for layers containing object geometry. This dynamic adaptation optimizes both energy efficiency and processing speed without compromising temperature uniformity in layers that require it.

Inventive Principle:

Principle #15Dynamics

2Productivity

If fusing energy is applied to all layers including empty ones, then temperature uniformity is maintained, but processing time increases

Engineering Contradiction:

Improveprocessing timeVSAvoidtemperature uniformity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs preliminary detection of empty layers before applying fusing energy. By analyzing the layer data in advance and identifying empty layers, the controller prepares a optimized processing plan that skips or reduces fusing energy application for these layers, thereby reducing processing time while maintaining temperature uniformity for layers that actually contain material to be fused.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies local quality by providing different thermal processing treatments to different layers based on their specific requirements. Empty layers receive minimal or no fusing energy, while non-empty layers receive full thermal processing. This localized approach ensures that temperature uniformity is maintained only where necessary (in layers with material), while accelerating processing for empty layers.

Inventive Principle:

Principle #3Local quality

3Productivity

If thermal processing is optimized for speed, then productivity increases, but thermal imbalances occur affecting quality

Engineering Contradiction:

Improveobject generation speedVSAvoidprinted object quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system incorporates feedback mechanisms that monitor layer characteristics and adjust thermal processing accordingly. By detecting empty layers and providing this information back to the controller, the system can optimize processing speed for empty layers while maintaining appropriate thermal processing for non-empty layers, thereby achieving high productivity without compromising manufacturing precision and printed object quality.

Inventive Principle:

Principle #23Feedback

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

This approach enhances the efficiency and speed of 3D printing by reducing energy consumption and allowing for faster object generation, while maintaining temperature uniformity and quality of printed objects.

Implementation Method 1

Fusing energy, for example from a fusing lamp, is then applied to the formed layer of build material. Energy is absorbed more readily where fusing agent is applied, which causes those portions of the build material on which fusing agent is applied to melt and coalesce

Methodology Applied

Scientific EffectElectromagnetic radiation heating: Absorption (EM radiation)

Implementation Method 2

causes those portions of the build material on which fusing agent is applied to melt and coalesce, or fuse, and subsequently solidify when cooled

Methodology Applied

Scientific EffectThermal melting: Melting

Implementation Method 3

pre-heats the layer of build material to close to its melting point

Methodology Applied

Scientific EffectThermal heating: Heating

Implementation Method 4

The build platform 102 is moveable in the z-axis (i.e. vertically)

Methodology Applied

Scientific EffectMechanical displacement: Displacement

Data Source

PatentUS11390032B2Conserving energy for empty 3D printing layers

Publication Date: 2022.07.19 PERIDOT PRINT LLC

AI summary

According to one aspect there is provided a three-dimensional printer. The printer comprises a controller to obtain data relating to a layer of a build model, to process non-empty layers according to a first operating mode and to process empty layers according to a second operating mode.