3D Printing Tool Paths for Continuous Multi-Layer Material Flow
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing 3D printing technologies face inefficiencies in path planning, particularly for advanced systems with multiple degrees of freedom, leading to excessive vibration, wear, and inability to maintain continuous material flow, especially in layer-by-layer approaches.
Innovation Solution
A method for determining a tool path that allows partial filling of higher build layers before completing lower layers, using predefined infill strategies and optimizing path continuity, minimizing jumps and intersections, and leveraging multi-axis capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If layer-by-layer path planning is used, then computational efficiency is improved, but manufacturing productivity deteriorates
Solution Approach 1:
The patent transitions from traditional 2D layer-by-layer path planning to 3D volumetric path planning. The system divides the build volume into multiple layers and generates toolpaths that can span across multiple layers simultaneously, utilizing the third dimension (build direction) to create continuous 3D paths. This allows the printing tool to deposit material across multiple layers without returning to the home position, significantly improving manufacturing productivity while maintaining computational efficiency through algorithmic optimization.
2Productivity
If Fractal space filling curves are used, then path continuity is improved, but manufacturing precision deteriorates due to excessive turns
Solution Approach 1:
The patent segments the build volume into multiple discrete layers and generates toolpaths for each layer independently, then combines them into a continuous 3D path. This segmentation approach avoids the excessive turns of Fractal curves by creating straight-line segments within each layer that connect smoothly across layer boundaries. The segmentation allows for optimized path planning within each layer while maintaining overall path continuity, thus improving manufacturing precision while preserving material deposition continuity.
Solution Approach 2:
The system dynamically adjusts the toolpath generation based on the specific geometry of each layer and the desired build orientation. Rather than using a fixed Fractal pattern, the path planning algorithm adapts to the actual part geometry, creating dynamic toolpaths that minimize turns and maximize straight-line deposition. This dynamic approach maintains material flow continuity while improving dimensional accuracy by reducing the harmful effects of excessive directional changes.
3Adaptability or versatility
If material feed is turned on and off during jump movements, then path flexibility is improved, but reliability deteriorates due to material deposition disturbances
Solution Approach 1:
The patent implements continuous material feed throughout the entire printing process, eliminating the need to turn the material feed on and off during jump movements. The continuous 3D toolpath is designed to minimize non-deposition movements, and when such movements are necessary, the material feed remains active. This approach maintains material flow stability and deposition quality while providing sufficient path flexibility through intelligent routing that accounts for robot kinematics and build geometry, thus improving reliability without sacrificing adaptability.
Data Source
AI summary
Described herein is a method (400) of determining a tool path for controlling a printing tool (100). Method (400) including step (401) of receiving an input file containing data indicative of a three dimensional structure to be formed. At step (404), the three dimensional structure is divided into a plurality of build layers, wherein build layers are separated in a build direction and each build layer extends laterally relative to the build direction. Each build layer includes an external contour defining the intersection of the build layer with an exterior surface of the three dimensional structure. At step (405) a tool path is defined which fills the three dimensional structure, wherein the path includes partially filling one or more higher build layers along the build direction before entirely filling at least one lower build layer. At step (406), a printing tool control algorithm is generated that includes a series of control commands for controlling the printing tool to move along the tool path to form the three dimensional structure.