3D Model Support Placement for Sensitive Surface Quality
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Solution Overview
Problem
In additive manufacturing, the mechanical removal of support structures from 3D printed objects is time-consuming and can cause surface damage or deformation, especially in sensitive areas, requiring manual intervention and increasing costs.
Innovation Solution
A method using a computer algorithm, potentially with a neural network, to strategically add support structures based on surface geometry and orientation, attributing quality degrees to surface segments to minimize support structure placement in sensitive areas, thereby reducing the need for manual post-processing and surface damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If support structures are added to ensure structural integrity during printing, then printing reliability is improved, but surface quality deteriorates due to mechanical post-processing damage
Solution Approach 1:
The patent applies local quality by differentiating surface segments into sensitive and non-sensitive regions, then selectively placing support structures only in non-sensitive areas. This ensures that critical surface regions are protected from mechanical post-processing damage while still providing necessary structural support where needed.
Solution Approach 2:
The patent performs preliminary action by pre-calculating and pre-planning support structure locations before the actual 3D printing process. The computer algorithm analyzes the 3D model, identifies sensitive surface segments, and determines optimal support placement in advance, preventing surface damage before it occurs.
2Ease of manufacture
If mechanical post-processing is used to remove support structures, then support removal is achieved, but time consumption increases and surface damage occurs
Solution Approach 1:
The patent extracts the harmful element (support structures) from sensitive surface areas by strategically placing them only in non-sensitive regions. This extraction principle eliminates the need for extensive manual post-processing of critical surfaces, reducing both time consumption and surface damage risks.
Solution Approach 2:
The patent enables self-service by designing support structures that are automatically removable through standard cleaning processes without requiring manual intervention. By placing supports in accessible, non-sensitive areas, the system allows the printed object to essentially remove its own supports through automated cleaning, freeing up manual post-processing time for higher-value tasks.
3Manufacturing precision
If manual post-processing is performed to protect sensitive surfaces, then surface quality is improved, but labor costs and time increase
Solution Approach 1:
The patent replaces the mechanical system of manual post-processing with a computational system. A computer algorithm automatically analyzes the 3D model, identifies sensitive surface segments, and determines optimal support placement, eliminating the need for manual assessment and intervention while maintaining high surface quality standards.
Solution Approach 2:
The patent introduces an intermediary computational layer between the 3D model and the physical printing process. The computer algorithm acts as a mediator that translates design requirements into optimized support structure placement, automatically protecting sensitive surfaces without requiring manual post-processing intervention.
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 the need for mechanical post-processing, minimizes surface artifacts and deformations, and decreases the time and cost associated with manual removal of support structures, while ensuring precise protection of sensitive surface segments.
Implementation Method 1
a 3D object is printed layer-by-layer through light-based curing of a liquid printing medium i.e., a liquid photocurable resin, which is selectively cured under the influence of UV radiation
Data Source
AI summary
A method of imposing quality requirements on a 3D model including support structures to be built by an additive manufacturing apparatus including: defining the surface geometry and the orientation of the 3D model with respect to the platform, the surface geometry includes surface segments. The method further includes attributing a degree of quality (L;H) to the surface segments respectively against post-processing for the subsequent removal of the support structures calculating, based on the defined orientation, the surface geometry and the degree of quality L;H) attributed; and adding the support structure to the 3D model based on the calculated positions and the degree of quality (L;H) attributed.