3D Printing Taper Compensation via Dynamic Spray Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing 3D printing techniques using cold spraying of metallic powder result in 3D objects with undesired tapering on their sides, which complicates the layer-by-layer construction and leads to reduced surface area with each subsequent layer.
Innovation Solution
A method involving a computerized controller that uses data defining 3D shape parameters to control an applicator, allowing for the spraying of metallic powder at a substrate and part-formed object to build the object in progressively applied layers. The controller calculates and adjusts the nozzle angle and spray parameters to fill in the initial inwardly tapered outer surfaces of the layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If spray material is applied in conventional cold spraying, then 3D objects can be built layer by layer, but the sides of the object develop undesired taper
Solution Approach 1:
The patent applies dynamics by making the spray parameters dynamic rather than static. The spray angle, distance, and material flow rate are continuously adjusted during the layer-by-layer construction process based on the current layer number and target shape requirements. This dynamic adjustment compensates for the natural tapering effect and enables both productive layer-by-layer construction and accurate shape control.
Solution Approach 2:
The patent employs parameter changes by systematically varying key spray parameters including spray angle, spray distance, and material flow rate across different layers. The control unit calculates optimal parameter values for each layer based on the target shape data, allowing the system to maintain uniform side surfaces while building the object layer by layer through progressive parameter adjustment.
2Quantity of substance
If the spray creates an inwardly tapered outer surface, then material deposition occurs, but subsequent layers have reduced surface area
Solution Approach 1:
The patent applies preliminary action by pre-calculating the spray parameters for each layer before deposition begins. The control unit uses the target shape data to determine the optimal spray angle, distance, and material flow rate needed to achieve the desired surface area for each layer, preventing the reduction of surface area that would normally occur with tapered deposition.
3Productivity
If conventional spray patterns are used, then material is deposited efficiently, but the 3D object shape accuracy deteriorates due to taper
Solution Approach 1:
The patent implements feedback through the control unit that continuously references the target shape data and adjusts spray parameters accordingly. The system uses the known target geometry to determine the appropriate spray parameters for each layer, creating a closed-loop control system that maintains both deposition efficiency and shape accuracy by adapting to the specific requirements of each layer.
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 method effectively addresses the tapering issue by allowing for precise control of the spray material application, resulting in 3D objects with improved surface uniformity and accuracy, enabling the creation of objects with straight edges and complex profiles.
Implementation Method 1
spray material is sprayed at the substrate... Optionally the spray is a cold spray and may comprise metallic powder
Data Source
AI summary
A method for forming a 3D object, comprising running control means with reference to data which defines 3D shape parameters of an object such that the control means: •uses the data to control an applicator to spray material at a substrate to build the object out of progressively applied layers, wherein at least some of the layers have an initial inwardly tapered outer edge; and •for at least some such layers causing the control means to use the data to move the applicator to apply spray material to fill in the taper.