3D Printing Insert Placement via Unfilled Region Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for building 3D objects using layer-based additive techniques face challenges in accurately incorporating embedded inserts, such as bolts or identification tags, due to difficulties in generating appropriate build data that ensures precise placement and minimizes interference from support materials.
Innovation Solution
A method for generating build sequence data that identifies insert locations, generates support layers, and creates unfilled regions in the CAD model to allow for accurate placement of inserts during the building process, using techniques like Boolean subtraction to prevent support materials from filling these regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If support layers are generated for overhanging portions of sliced layers, then structural support during fabrication is improved, but interference with embedded insert placement occurs
Solution Approach 1:
The build volume is segmented into filled regions and unfilled regions. The unfilled regions are specifically created to accommodate embedded inserts, while filled regions provide structural support. This segmentation allows support layers to be generated only where needed without interfering with insert placement locations.
Solution Approach 2:
Different regions of the build volume are assigned different properties: filled regions receive support layers for structural stability, while unfilled regions remain clear for insert placement. The build data locally distinguishes between these regions to provide appropriate support only where required.
2Stability of the object's composition
If standard slicing and support generation is used, then fabrication stability is improved, but complexity of generating accurate build data increases
Solution Approach 1:
The locations of embedded inserts are identified and unfilled regions are created in advance during the build data generation process, before support layers are generated. This preliminary action simplifies subsequent support generation by pre-defining where support should and should not be placed.
Solution Approach 2:
An intermediary data structure representing unfilled regions is introduced between the CAD model and the final build paths. This intermediary layer facilitates the integration of insert locations with the support generation process, reducing overall system complexity.
3Manufacturing precision
If unfilled regions are created at insert locations, then insert placement accuracy is improved, but volume of build material required increases
Solution Approach 1:
Material is extracted from specific regions to create unfilled spaces where inserts will be placed. This removal of material only occurs where necessary for insert accommodation, minimizing the overall increase in build volume while ensuring accurate insert placement.
Data Source
AI summary
A method for generating build sequence data for a computer-aided design model of a three-dimensional object, the method comprising identifying a location of an insert data representation in the computer-aided design model, slicing the computer-aided design model into a plurality of sliced layers, generating a plurality of support layers for at least a portion of the plurality of sliced layers, and generating an unfilled region in the computer-aided design model at the identified location of the insert data representation.