3D Printing Tool Path Planning for Continuous Multi-Layer Deposition
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing techniques face inefficiencies due to a rigid, layer-by-layer approach in tool path planning, which does not fully utilize the degrees of freedom in three-axis systems, especially with advanced systems involving 6-axis robot arms. This leads to excessive vibration, wear, and limitations in high-speed movement due to high numbers of directional changes in the tool path.
Innovation Solution
A method for determining a tool path that involves receiving input data for a three-dimensional structure, dividing it into build layers, and defining a tool path that partially fills higher layers before entirely filling lower layers. This approach allows for continuous material flow and reduces the need for frequent tool deactivations and reactivations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a rigid layer-by-layer path planning approach is used, then computational efficiency is improved, but the system does not take advantage of available degrees of freedom and results in excessive vibration and wear
Solution Approach 1:
The patent transitions from traditional 2D layer-by-layer path planning to 3D continuous path planning that utilizes the Z-axis and rotational degrees of freedom. The system generates toolpaths that move freely through 3D space rather than being constrained to complete each layer before moving to the next, thereby exploiting the full six-degree-of-freedom capability of robotic manipulators while maintaining computational feasibility.
Solution Approach 2:
The patent implements dynamic path planning that adapts to the specific geometry of the object being manufactured. Rather than following a fixed layer-by-layer sequence, the system dynamically generates continuous toolpaths that optimize for robotic motion capabilities, reducing unnecessary accelerations and decelerations while maintaining manufacturing precision.
2Area of stationary object
If Fractal space filling curves such as Peano curves and Hilbert curves are used, then path coverage is improved, but the number of turns becomes too high causing excessive vibration and wear
Solution Approach 1:
The patent segments the manufacturing space into volumetric regions rather than planar layers, allowing the toolpath to continuously traverse through these segments in 3D space. This segmentation approach enables complete area coverage while minimizing the number of directional changes by allowing the tool to move vertically and diagonally through segments rather than repeatedly turning within planar layers.
Solution Approach 2:
The patent employs curved and continuous toolpaths that smoothly transition between directions rather than using sharp angular turns characteristic of fractal curves. The continuous curvature of the generated paths reduces mechanical shock and vibration while maintaining comprehensive coverage of the manufacturing volume.
3Adaptability or versatility
If modular path planning with partitioning of individual object layers is used, then path planning flexibility is improved, but deposition is not continuous and the tool must be deactivated and reactivated multiple times
Solution Approach 1:
The patent generates continuous toolpaths that maintain material deposition throughout the entire manufacturing process. By planning paths in 3D space rather than 2D layers, the system eliminates the need to stop deposition at layer boundaries, allowing the robotic manipulator to continuously deposit material while moving through the volumetric build space, thereby maximizing productivity and material utilization.
Solution Approach 2:
The patent merges multiple layer paths into a single continuous 3D path that traverses through multiple layers simultaneously. This combining approach integrates what would traditionally be separate layer completions into one unified continuous operation, eliminating the need for repeated tool deactivation and reactivation while maintaining the flexibility to adapt to complex geometries.
4Productivity
If high-speed movement is required, then productivity is improved, but sufficient path length over which to accelerate and reach constant velocity is limited due to frequent directional changes
Solution Approach 1:
The patent utilizes the third dimension (Z-axis) and rotational degrees of freedom to create longer, more gradual acceleration paths. Rather than being constrained to 2D planar movements with frequent turns, the toolpath can extend in 3D space, providing sufficient distance for the robotic manipulator to accelerate to high speeds and maintain constant velocity, thereby enabling high-speed manufacturing.
Data Source
AI summary
A method of determining a tool path for controlling a printing tool, including step (401) of receiving an input file containing data indicative of a three-dimensional structure to be formed. At step (404) the structure is divided into a plurality of build layers, which are separated in a build direction and each layer extends laterally relative to the build direction. Each layer includes an external contour defining the intersection of the layer with an exterior surface of the three-dimensional structure. Step (405) defines a tool path, 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.