3D Printing Support Structure Layout for Material-Efficient Overhang Support
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Solution Overview
Problem
Existing 3D printing systems face challenges in defining support structures that are strong enough to support 3D objects while minimizing material and space usage, often resulting in inefficient use of resources and potential structural failure.
Innovation Solution
A method and system for predefining improved support structures by analyzing 3D digital models to identify slices that require support, selecting preceding and subsequent slices for support regions, and defining support structures that gradually increase in width to meet specified thresholds, thereby optimizing space and material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional support structures are used to support overhanging surfaces and negative angle surfaces, then structural integrity is maintained, but material usage and space occupation increase significantly
Solution Approach 1:
The system performs preliminary analysis of the 3D model to identify regions requiring support before actual printing begins. By pre-defining support structures based on geometric rules and body region characteristics, the system optimizes material placement from the outset, avoiding unnecessary support material while ensuring structural integrity where needed.
Solution Approach 2:
The patent applies support structures selectively based on local characteristics of body regions. By analyzing specific geometric properties (width, depth, orientation) of different regions and applying support only where geometric rules indicate it's necessary, the system provides localised quality support rather than uniform support throughout the entire model, reducing overall material consumption.
2Reliability
If traditional support structures are used to support overhanging surfaces and negative angle surfaces, then structural integrity is maintained, but space occupation on fabrication tray increases
Solution Approach 1:
The system performs preliminary analysis of the 3D model to identify regions requiring support before actual printing begins. By pre-defining support structures based on geometric rules and body region characteristics, the system optimizes space placement from the outset, positioning support structures efficiently to minimize footprint on the fabrication tray while maintaining structural integrity.
Solution Approach 2:
The patent applies support structures selectively based on local characteristics of body regions. By analyzing specific geometric properties (width, depth, orientation) of different regions and applying support only where geometric rules indicate it's necessary, the system reduces the overall spatial footprint of support structures on the fabrication tray.
3Loss of substance
If support structures are reduced to minimize material usage, then material efficiency improves, but risk of structural failure increases
Solution Approach 1:
The system incorporates feedback mechanisms by analyzing the results of support structure definition and adjusting the placement and dimensions of support structures based on geometric rule evaluations. The iterative analysis of body region characteristics and support requirements ensures that support structures are optimally positioned to prevent structural failure while minimizing material usage.
Solution Approach 2:
The patent utilizes parameter changes by adjusting the geometric properties of support structures (width, height, position) based on the specific characteristics of body regions. By dynamically modifying support structure parameters according to local geometric rules and body region properties, the system maintains structural integrity while optimizing material efficiency.
Data Source
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Figure 2C~2D
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.