3D Printing Toolpath Width Control for Gap-Free Infill
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Solution Overview
Problem
Existing methods for manufacturing three-dimensional shaped objects often result in gap regions due to incomplete filling of bulk cluster paths, which can lead to defects in the final product.
Innovation Solution
A method involving the generation of path data and line width information for shaping materials, where the line width in each partial path is determined based on the distance between side edges or contour lines, allowing for precise control of material discharge to prevent gap formation during the stacking process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bulk cluster path is used to fill the interior region, then productivity is improved by reducing the number of paths, but gap regions are generated due to incomplete filling
Solution Approach 1:
The bulk cluster path is segmented into multiple partial paths that follow the contour lines of the object. Each partial path is discrete and can be precisely controlled, allowing complete filling of the interior region while maintaining high productivity. The segmentation transforms the continuous bulk cluster approach into manageable discrete segments that eliminate gap formation.
Solution Approach 2:
The line width of the shaping material is dynamically adjusted based on the distance between adjacent contour lines. When the distance is large, a wider line width is used to ensure complete filling; when the distance is small, a narrower line width is used to prevent overlap. This dynamic adjustment allows the bulk cluster path to effectively fill the interior region without generating gaps, resolving the contradiction between productivity and manufacturing precision.
2Manufacturing precision
If line width is increased to prevent gaps, then manufacturing precision is improved, but the distance between adjacent paths must be larger reducing adaptability
Solution Approach 1:
The line width is dynamically determined based on the actual distance between adjacent contour lines for each partial path. This dynamic adjustment allows the system to adapt to varying spacing requirements throughout the interior region, maintaining manufacturing precision (gap prevention) while preserving adaptability to different geometric configurations. The line width is not fixed but varies locally to match the local spacing requirements.
Solution Approach 2:
Different line widths are applied to different partial paths based on their local geometric characteristics. Partial paths with larger distances between contour lines receive wider line widths, while partial paths with smaller distances receive narrower line widths. This local quality approach ensures gap prevention where needed while maintaining adaptability in regions with varying spacing requirements.
3Manufacturing precision
If multiple residual paths are generated to fill gap regions, then manufacturing precision is improved by preventing gaps, but device complexity increases
Solution Approach 1:
The interior region is segmented into multiple partial paths based on contour lines, and the line width of each partial path is independently determined based on local spacing. This segmentation approach simplifies the overall path generation process by breaking it down into manageable discrete segments, each with its own optimized line width, thereby reducing device complexity while maintaining manufacturing precision.
Solution Approach 2:
The line width for each partial path is dynamically calculated based on the distance between adjacent contour lines, eliminating the need for manual specification of multiple residual paths. This dynamic determination simplifies the path generation process by automatically adapting the line width to local geometric requirements, reducing device complexity while ensuring complete filling without gaps.
Data Source
AI summary
To provide a method for manufacturing a three-dimensional shaped object in which a three-dimensional shaped object is manufactured by discharging a shaping material from a discharge unit toward a stage to stack a layer, the method for manufacturing a three-dimensional shaped object includes: a first step of generating path data having a plurality of partial paths through which the discharge unit moves while discharging the shaping material; a second step of determining a line width of the shaping material in each of the partial paths and generating line width information for implementing the line width; a third step of generating shaping data including the path data and the line width information; and a fourth step of shaping the three-dimensional shaped object according to the shaping data. In the second step, the line width in a target path that is one of the partial paths is determined in accordance with a distance between a first wall and a second wall separated by the target path. The first wall and the second wall are side edges of the shaping material discharged in the partial path generated before the target path or a contour line of the three-dimensional shaped object.