Additive Part Build-Line Prediction with Ray-Shooting Analysis
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Solution Overview
Problem
Current methods for determining build lines in additive manufacturing are expensive, time-consuming, and prone to errors, requiring manual prototyping and observation.
Innovation Solution
A build line prediction system that analyzes a 3D model to predict the presence and location of build lines using a build line analyzer module, which interrogates face count and surface area differences between layers, and employs ray-shooting analysis to identify precise locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual prototyping and observation methods are used to determine build lines, then build line detection is possible, but the process becomes expensive, time-consuming, and prone to errors
Solution Approach 1:
The patent performs build line prediction computations before actual additive manufacturing takes place. The system analyzes the 3D model, slices it into layers, and predicts build line locations in advance using computational algorithms that evaluate layer geometry changes, allowing designers to identify and mitigate build line issues before physical prototyping begins
Solution Approach 2:
The patent creates a virtual digital copy of the build process through computational modeling. Instead of physically manufacturing test parts to observe build lines, the system uses ray-shooting analysis and layer comparison algorithms to generate a virtual prediction of where build lines will occur, replacing expensive physical trial-and-error with efficient digital simulation
2Productivity
If computational prediction methods are implemented, then prototyping time is reduced, but system complexity increases
Solution Approach 1:
The patent introduces a build line prediction system as an intermediary between the 3D model design stage and the actual additive manufacturing process. This computational mediator analyzes layer geometry, performs ray-shooting simulations, and provides predictions that guide design adjustments, acting as a bridge that translates complex manufacturing physics into actionable design insights without requiring full system redesign
Solution Approach 2:
The patent divides the build process into discrete layers and analyzes each layer pair independently. By slicing the 3D model into thin cross-sections and comparing adjacent layers for geometric changes that indicate potential build lines, the system breaks down a complex continuous manufacturing process into manageable discrete units that can be processed and predicted separately
Data Source
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AI summary
A method for predicting build line locations in a part before additively manufacturing the part, includes obtaining a sliced three-dimensional model 130 of a part for additive manufacturing, generating, for each neighboring pair of layers 381, 382, 481, 482 in the plurality of layers 280, a face count difference, generating, for each of the neighboring pair of layers, a surface area difference, predicting, for each of the neighboring pair of layers, that the first layer from each of the neighboring pair of layers comprises a presence of a build line based on a determination that the face count difference is less than zero and the surface area difference is greater than zero; storing a list of predicted build line layers comprising the one or more layers predicted to comprise the presence of the build line; and adjusting dimensions of the part for additive manufacturing corresponding to a layer in the list of predicted build line layers.