3D Printing Tool Paths for Curved Composite Surface Deposition
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Solution Overview
Problem
Existing 3D printing methods lack the capability to generate fine-grained, automated tool paths for complex curved surfaces, particularly for composite materials, which limits the realization of anisotropic properties such as strength, stiffness, and thermal conductivity.
Innovation Solution
A method involving the generation of parametric representations of 3D objects, where a first edge is selected based on fiber direction, and a second edge is computed parallel to it, allowing for the creation of tool paths with constant width to optimize the deposition of materials along preferred fiber directions, enabling the printing of complex geometries with improved structural and thermal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional slice algorithms are used for filament deposition method, then the printing process can be completed, but the tool path cannot be fine controlled to take advantage of preferred fiber directions
Solution Approach 1:
The patent segments the tool path generation process into distinct modules: (1) generating initial tool paths using conventional slice algorithms, (2) identifying preferred fiber directions through finite element analysis, (3) adjusting tool paths to align with fiber directions, and (4) optimizing deposition parameters. This segmentation allows fine control of tool paths while managing algorithmic complexity through modular processing steps.
Solution Approach 2:
The patent performs preliminary finite element analysis before tool path generation to determine preferred fiber directions and stress distributions. This preliminary action enables the subsequent tool path optimization to be guided by pre-calculated structural requirements, improving manufacturing precision without requiring real-time complex calculations during printing.
2Productivity
If automated tool path decision process is implemented, then productivity can be improved, but it becomes difficult to handle complex geometries
Solution Approach 1:
The patent introduces finite element analysis as an intermediary between the complex geometry input and the automated tool path generation. The FEA model acts as a mediator that translates complex geometric and material properties into simplified stress and strain data, which then guides the automated tool path optimization. This intermediary enables high-level automation while maintaining adaptability to complex geometries through physics-based guidance.
Solution Approach 2:
The patent dynamically changes tool path parameters (such as deposition angle, layer orientation, and fiber alignment) based on locally varying stress and strain parameters obtained from finite element analysis. This parameter adaptation allows the automated system to handle complex geometries by adjusting local deposition characteristics according to structural requirements, maintaining both productivity and geometry handling capability.
3Reliability
If existing methods are used for 3D printing, then the printing process can be completed, but the anisotropic nature of printed parts cannot be fully accounted for
Solution Approach 1:
The patent implements a feedback loop where finite element analysis of the designed part structure informs tool path generation, which in turn affects the actual printed structure. The process uses stress and strain feedback from FEA to adjust fiber orientation and deposition patterns, ensuring the anisotropic properties of the printed part match the design requirements. This feedback mechanism improves structural reliability while managing process complexity through iterative optimization.
Solution Approach 2:
The patent explicitly addresses the anisotropic nature of composite materials by aligning fiber reinforcement directions with principal stress trajectories determined through finite element analysis. The tool path generation process creates layered composite structures where each layer's fiber orientation is optimized for the local stress state, fully accounting for the anisotropic mechanical properties of the printed composite parts.
Data Source
AI summary
The present disclosure provides methods and systems for printing a three-dimensional (3D) object. A method for printing a 3D object may comprise receiving a computer model of the 3D object in computer memory and generating a parametric representation of the computer model of the 3D object. Next, a first edge in a parametric representation of a curved surface of the computer model may be selected, and a 3D tool path may be generated at least in part by: (i) selecting a first set of points on the first edge; and (ii) computing coordinates of a second set of points on a second edge parallel to the first edge in the parametric representation, wherein the first edge and the second edge define the 3D tool path. Printing instructions may then be generated for printing at least a portion of the 3D object along the tool path.