Adaptive Layer Thickness for 3D Printing Precision

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Solution Overview

Problem

Existing additive manufacturing methods, such as adaptive slicing, are inefficient in reducing printing duration without compromising printing quality, especially for dental 3D objects where varying precision requirements are not adequately addressed, leading to longer printing times and potential quality issues.

Innovation Solution

A modified adaptive slicing method that allows selective imposition of different precision requirements on surface elements based on their inclination, enabling finer layers for high precision areas and coarser layers for low precision areas, thereby optimizing printing duration and accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If thin layers are used throughout the entire 3D model to achieve high resolution in the z-direction, then manufacturing precision is improved, but printing duration increases significantly

Engineering Contradiction:
Improveresolution in z-directionVSAvoidprinting speed
Core Design Contradiction:
Manufacturing precisionVSProductivity

Solution Approach 1:

The patent applies different layer thicknesses to different regions of the 3D model based on local geometry requirements. Surface elements are classified into first regions (requiring thin layers for high precision) and second regions (tolerating thick layers). This local differentiation allows thin layers to be used only where geometrically necessary, while thick layers are used in regions where they suffice, thereby reducing total printing duration while maintaining required precision in critical areas.

Inventive Principle:
Principle #3Local quality

2Productivity

If adaptive slicing is used to calculate local layer thicknesses based on normal vector inclination, then printing duration is reduced, but the precision requirement cannot be flexibly adjusted for different surface elements

Engineering Contradiction:
Improveprinting durationVSAvoidprecision requirement flexibility
Core Design Contradiction:
ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent introduces a dynamic precision requirement parameter that can be selectively assigned to different surface elements. Instead of a fixed precision requirement throughout the model, the system allows the precision requirement to vary dynamically across different regions. This enables flexible adjustment where high precision is required in certain areas (first regions) while lower precision suffices in others (second regions), optimizing both printing duration and quality according to specific application needs.

Inventive Principle:
Principle #15Dynamics

3Stability of the object's composition

If the same precision requirement is applied to all surface elements, then consistency is maintained, but printing time cannot be optimized for areas where high precision is not necessary

Engineering Contradiction:
Improveprecision consistencyVSAvoidprinting duration
Core Design Contradiction:
Stability of the object's compositionVSProductivity

Solution Approach 1:

The patent divides the 3D model into different regions with different precision requirements. First regions (such as spherical surfaces or areas requiring high geometric fidelity) are assigned thin layers and high precision requirements, while second regions (such as planar surfaces or areas where coarse approximation is acceptable) are assigned thick layers and lower precision requirements. This local quality differentiation maintains precision consistency only where necessary, while allowing productivity optimization in regions where high precision is not critical.

Inventive Principle:
Principle #3Local quality

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 accelerates the printing process by reducing unnecessary layers while maintaining or enhancing printing accuracy, particularly beneficial for dental models like drilling templates where precision varies across surfaces.

Implementation Method 1

a three-dimensional model 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

Methodology Applied
Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentUS12086936B2Method of determining layer thicknesses of 3D models for additive manufacturing
Publication Date: 2024.09.10 DENTSPLY SIRONA INC
  • US12086936B2 patent drawing
  • US12086936B2 patent drawing
  • US12086936B2 patent drawing

AI summary

The present invention relates to a method of determining layer thicknesses of a three-dimensional model for generation with an additive manufacturing apparatus. The method includes: a step of determining the layer thicknesses according to an adaptive slicing algorithm in which the thickness of a layer is calculated through a relation based on the inclination of the normal vectors of the surface elements of the 3D model partly enclose the layer from a horizontal direction (x;y).