3D Model Slicing With Adaptive Layer Orientation and Thickness
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Solution Overview
Problem
Conventional additive manufacturing methods, such as uniform horizontal slicing, adaptive horizontal slicing, and directional slicing, fail to adapt slice thickness and orientation effectively along the object's axial direction, leading to poor dimensional accuracy and surface finish, especially at regions with large local curvatures or steep slopes.
Innovation Solution
A method and system that determine the thickness and orientation of slicing layers iteratively based on the difference between consecutive layers, using the area of the slicing layers to adjust thickness and calculating orientations through intersection points and centroids to adapt to local curvatures, allowing for adaptive directional slicing and 6-DoF print head trajectories.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If uniform horizontal slicing with constant layer thickness is used, then the slicing process is simple and fast, but the surface finish and dimensional accuracy are poor, especially at regions with large local curvatures or steep slopes
Solution Approach 1:
The patent implements dynamic slicing by making the slicing plane orientation and layer thickness variable rather than fixed. The slicing plane normal vector is dynamically adjusted to align with the local axial direction of the 3D object, and the layer thickness is dynamically modified based on local curvature and slope characteristics. This dynamic approach resolves the contradiction by enabling fast processing through automated adaptation while achieving high surface finish and dimensional accuracy through local optimization.
Solution Approach 2:
The patent applies local quality by differentiating the slicing parameters across different regions of the 3D object. Regions with large local curvatures or steep slopes receive specialized treatment with adjusted slicing plane orientations and modified layer thicknesses, while other regions use standard parameters. This localized optimization resolves the contradiction by improving surface finish and dimensional accuracy where needed without unnecessarily complicating the entire slicing process.
2Manufacturing precision
If adaptive horizontal slicing with variable layer thickness is used, then the surface quality is improved, but the slicing plane orientation cannot be adapted along the object's axial direction
Solution Approach 1:
The patent extends adaptive slicing by making both the slicing plane orientation and layer thickness dynamic variables. The slicing plane normal vector is calculated to align with the local axial direction at each slicing position, enabling the orientation to adapt continuously along the object's axial direction. This dynamic dual-parameter adjustment resolves the contradiction by simultaneously achieving improved surface quality through variable thickness and enhanced adaptability through orientation adjustment.
3Adaptability or versatility
If conventional directional slicing is used, then the slicing plane orientation can be aligned with the object's axial direction, but the slice thickness cannot be adapted along the axial direction and adjacent slices must intersect
Solution Approach 1:
The patent makes both slicing plane orientation and layer thickness dynamic parameters that can be independently optimized. The slicing plane normal vector is dynamically calculated to align with the local axial direction, while the layer thickness is dynamically adjusted based on local geometric characteristics such as curvature and slope. This resolves the contradiction by enabling both orientation alignment and thickness adaptation without requiring adjacent slices to intersect, as each slice's parameters are independently optimized.
4Ease of manufacture
If conventional slicing methods are used, then the process is straightforward, but the print head trajectory fails to adapt to local curvatures of inclination angle
Solution Approach 1:
The patent implements dynamic slicing parameters that directly inform the print head trajectory planning. The slicing plane orientation and layer thickness are dynamically adjusted to match the local axial direction and geometric characteristics, which in turn guides the print head to follow trajectories that adapt to local curvatures and inclination angles. This resolves the contradiction by maintaining process simplicity through automated calculation while achieving high material deposition accuracy through adaptive trajectory generation.
Data Source
AI summary
There is provided a method of additive manufacturing using at least one processor, the method includes: determining a first slicing layer of a three-dimensional (3D) model of a 3D object; determining a second slicing layer of the 3D model based on the first slicing layer, the second slicing layer being immediately subsequent to the first slicing layer; and determining a thickness of the second slicing layer and an orientation for a third slicing layer of the 3D model based on a difference between the second slicing layer and the first slicing layer, the third slicing layer being immediately subsequent to the second slicing layer. There is also provided a corresponding system and computer program product for additive manufacturing.