3D Printing Infill Path Generation for Void Elimination
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Solution Overview
Problem
Existing methods for manufacturing three-dimensional shaped objects often result in void areas due to residual paths, which can lead to gaps and reduced strength in the final product.
Innovation Solution
A method involving the generation of first and second discharge paths, where the second path is formed by a series of polygons with stepwise changing sizes from the outermost circumference to the central area of the infill region, ensuring a continuous path that prevents voids and enhances the structural integrity of the object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a bulk cluster path is used to fill the infill area, then the filling efficiency is improved, but void areas are generated leading to gaps and reduced strength
Solution Approach 1:
The infill area is divided into multiple regions based on distance from the outer shell, with each region filled by a separate discharge path. The infill area is segmented into first infill areas (closer to outer shell) and second infill areas (closer to center), allowing systematic coverage without voids while maintaining filling efficiency
Solution Approach 2:
The patent introduces a radial dimension for path generation, creating discharge paths that extend from the outer shell toward the center along radial directions. This dimensional approach ensures complete coverage of the infill area without generating voids, while the paths are arranged to maintain efficient material deposition
2Manufacturing precision
If a residual path is generated in the void area, then gaps are prevented, but the path planning complexity increases
Solution Approach 1:
The discharge paths are planned in advance to systematically cover the entire infill area without generating voids. The path planning algorithm pre-calculates optimal trajectories that ensure complete coverage, eliminating the need for corrective residual paths and reducing overall path planning complexity
Solution Approach 2:
The patent employs curved or spiral discharge paths that smoothly traverse the infill area, rather than simple linear patterns. These curved paths naturally fill the space between the outer shell and center area, ensuring complete coverage while maintaining manageable path complexity through smooth continuous trajectories
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. The method for manufacturing a three-dimensional shaped object includes: (A) a step of generating first shaping data including information on a first discharge path for forming an outer shell shape of the three-dimensional shaped object, and information for specifying a line width of the first discharge path; (B) a step of generating second shaping data including information on a second discharge path for filling an infill area that is an inner side portion of the outer shell shape, and information for specifying a line width of the second discharge path; and (C) a step of shaping the three-dimensional shaped object according to the first shaping data and the second shaping data. In step (B), a path indicating a plurality of polygons whose sizes change in a stepwise manner from a shape along an outermost circumference of the infill area to a shape of a central area of the infill area is generated as the second discharge path.