3D Volumetric Printing Path Control for Complex Freeform Objects
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Solution Overview
Problem
Existing additive manufacturing methods for 3-dimensional objects, such as rapid liquid printing, are limited by the need for layer-by-layer slicing, which can lead to mismatches between initial 3D data and printing parameters, and restrict geometric forms and surface structures, especially when using flexible or elastic materials.
Innovation Solution
A method that determines a printing path and adjusts the volumetric flow rate and velocity of the insertion needle to directly produce the desired 3D shape without slicing, allowing for variable wall thickness and surface modulation, and enables the use of different materials and colors along the path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If layer-by-layer slicing is used for additive manufacturing, then the manufacturing process is simplified and easier to control, but the geometric forms and surface structures are restricted and mismatches occur between initial 3D data and printing parameters
Solution Approach 1:
The patent transitions from traditional 2D layer-by-layer slicing to 3D volumetric printing by moving the insertion needle through the support material along a defined path, enabling direct formation of complex 3D geometries without step artifacts. This dimensional approach allows continuous material deposition through the entire object volume, preserving geometric complexity and surface quality while maintaining process control.
2Device complexity
If layer-by-layer slicing is used, then the printing path determination is simplified, but the production speed decreases and printing effort increases
Solution Approach 1:
The patent implements continuous material deposition through the support material by moving the insertion needle along a continuous path, eliminating the need for repeated layer-by-layer slicing operations. This continuous action significantly reduces printing time and effort while the system automatically determines the optimal path based on the 3D model, maintaining manageable complexity through algorithmic path planning.
3Extent of automation
If conventional additive manufacturing is used, then the manufacturing process is standardized, but the wall thickness and surface structure are limited to uniform values
Solution Approach 1:
The patent enables local variation in wall thickness and surface structure by controlling the insertion needle's path and material deposition rate at different locations. The system can adjust these parameters dynamically along the printing path to create regions with different thicknesses and surface characteristics, while maintaining overall process standardization through automated path planning and material delivery control.
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 reduces printing effort and complexity, enables smoother surfaces, and allows for more complex geometric forms and material variations, improving production speed and flexibility.
Implementation Method 1
a base body material in a flowable state is introduced into a support material by at least one insertion needle and cures therein at least partially
Implementation Method 2
The term 'curing' in the following also includes cross-linking or other reactions or changes in the properties of the production material which lead to an increase in dimensional stability
Data Source
AI summary
A method for producing a 3-dimensional object having a base body which is produced in an additive manufacturing process, in which a base body material in a flowable state is introduced into a support material by at least one insertion needle and cures therein at least partially, wherein the method has the following steps: Providing data of the object to be produced, which contain information about its 3-dimensional shape, determining printing parameters from the data provided, wherein a printing path is determined along which the insertion needle is moved through the support material, and a volumetric flow rate of the base body material inserted into the support material and/or the velocity of the insertion needle at each point along the printing path are determined, producing the base body by means of the additive manufacturing process using the determined printing parameters.