Additive Manufacturing Layer Orientation via Distance Field
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Solution Overview
Problem
Current additive manufacturing processes are limited by linear portal kinematics, which restrict the process head's ability to orient itself, necessitating support structures for complex geometries like those with holes or protrusions, limiting the production of components without support materials.
Innovation Solution
The method involves calculating a distance field to determine isosurfaces for layer formation, allowing for the creation of free-form, three-dimensional layers that adapt to the component geometry, enabling the use of multi-axis movement kinematics and eliminating the need for support structures by orienting the process head and adjusting orientation vectors to avoid collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If linear portal kinematics with three movement axes are used to guide the process head, then the system is simple and easy to control, but the process head cannot orient itself and support structures are required for complex geometries
Solution Approach 1:
The patent transitions from 3-axis linear portal kinematics to 5-axis or multi-axis movement kinematics, adding rotational degrees of freedom. This enables the process head to orient itself in multiple directions, eliminating the need for support structures while manufacturing complex geometries with holes and protrusions.
Solution Approach 2:
The system evolves from static linear movement to dynamic multi-axis kinematics where the process head can actively orient itself during manufacturing. The movement kinematics adapt to the geometry being manufactured, allowing real-time orientation changes without requiring support structures.
2Ease of manufacture
If support structures are used to manufacture complex geometries without holes or protrusions, then the component can be manufactured, but manufacturing time increases and support material must be removed afterward
Solution Approach 1:
The patent performs preliminary geometry decomposition and path planning before manufacturing, calculating optimal layer orientations and process head movements in advance. This prevents the need for support structures during manufacturing, eliminating both the manufacturing time for supports and the subsequent removal time.
Solution Approach 2:
The system changes the orientation parameters of layers dynamically during manufacturing. By calculating and adjusting layer orientations based on geometry analysis, the process can manufacture complex features without support structures, significantly reducing total manufacturing time.
3Ease of manufacture
If conventional layer decomposition strategies are used, then the process is simple to implement, but geometries with holes or protrusions require support structures
Solution Approach 1:
The patent segments the component geometry into multiple layers with varying orientations. By decomposing the 3D geometry and analyzing each layer's characteristics, the system can determine optimal orientations that eliminate the need for support structures, particularly for geometries with holes and protrusions.
Solution Approach 2:
The system performs preliminary analysis of the digital model to identify geometries that would require support structures with conventional methods. Based on this analysis, it calculates optimized layer orientations in advance, preventing support material usage before manufacturing begins.
Data Source
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AI summary
The invention relates to a method for additive manufacture of a three-dimensional object, which method is based on a digital model, in which at least one starting area is defined on a surface of the digital model and, beginning on said at least one starting area, a layered sub-division of the model takes place. The layers are successively built up additively to produce the three-dimensional object. The positioning and arrangement of the layers based on the at least one starting area takes place on the basis of the calculation of a distance field, which assigns to each point of the model volume the shortest distance within the volume to the nearest starting area. For each discrete point of a layer defined by a distance field an orientation of a processing head is determined, wherein in particular either the surface normal of the layer is calculated or the gradient vectors of the distance field are calculated, which show the direction of the steepest rise in the distances for the discrete point. The shape and distribution of the layers is adapted to the shape of the digital model. The sequence for the adaptive construction results from the assignment of the layers to distance values, beginning with the lowest distance value in ascending order.