3D Printing Support Structure Layout for Lower Material Waste
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Solution Overview
Problem
Current 3D inkjet printing systems face challenges in defining support structures that are strong enough to support printed objects while minimizing material usage and space occupancy on the fabrication tray, often resulting in either inadequate support or excessive material waste.
Innovation Solution
A method and system for defining improved support structures by analyzing 3D digital models, identifying slices that require support, and determining if they meet specific rules regarding width, distance, and length thresholds, allowing for the gradual increase in support region width across preceding slices to form optimized support structures that are strong yet space-efficient.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional support structures are used to support overhangs and negative angle surfaces, then the printed object can be properly supported, but excessive material is consumed and space on the fabrication tray is occupied
Solution Approach 1:
The support structure is divided into multiple segments corresponding to different slices of the 3D object. Each slice's support region is independently determined based on whether it meets predetermined rules, allowing the support structure to be segmented into necessary and unnecessary portions, thereby reducing material consumption while maintaining support strength where needed
Solution Approach 2:
The patent applies different support strategies to different regions of the 3D object. By evaluating each slice's body region against predetermined rules (width threshold, distance threshold, length threshold), the system provides support only where locally necessary, rather than using uniform support structures throughout, thus optimizing material usage while maintaining reliability
2Reliability
If traditional support structures are used to support overhangs and negative angle surfaces, then the printed object can be properly supported, but space on the fabrication tray is excessively occupied
Solution Approach 1:
The patent extracts and removes unnecessary support regions from the support structure by evaluating each slice against predetermined rules. Slices that do not meet the rules (such as those with sufficient width, adequate distance from previous body regions, or appropriate length) have their support regions removed, reducing fabrication tray occupancy while maintaining support strength where actually needed
3Loss of substance
If support structures are minimized to reduce material usage, then material consumption is reduced, but the support strength may become insufficient
Solution Approach 1:
The patent implements a feedback mechanism by evaluating each slice's body region against predetermined rules (width threshold, distance threshold, length threshold) and adjusting the support structure accordingly. This feedback loop ensures that support is maintained where necessary (when rules are not met) while minimizing support where possible (when rules are satisfied), optimizing the balance between material usage and support strength
Data Source
AI summary
Systems and methods for predefining at least one support structure for at least one three-dimensional object for printing thereof using a three-dimensional printing system are disclosed. Default support structures are replaced by improved support structures or not depending on the result of an assessment, based on predefined rules of the body region in the slice that needs support.