Additive Manufacturing Settings for 3D Objects
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Additive manufacturing systems face challenges in maintaining geometric accuracy and preventing thermal-related part quality issues such as over-fusing, under-fusion, warpage, bubbles, and elephant skins, particularly for large or small 3D printed objects.
Innovation Solution
The method involves determining the characteristics of 3D objects to be printed, grouping them based on similar characteristics, and adjusting additive manufacturing settings accordingly. This includes altering parameters such as bed temperature, energy source temperature, agent deposition, and packing orientation to optimize the printing process for each group of objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If additive manufacturing settings are optimized for large objects, then thermal-related issues such as over-fusing are reduced, but geometric accuracy and fusion quality deteriorate for small objects
Solution Approach 1:
The patent segments objects into different size categories (small, medium, large) and applies different manufacturing settings to each segment. This allows optimization of thermal control for large objects while maintaining geometric accuracy for small objects, resolving the contradiction between preventing over-fusing and maintaining precision.
Solution Approach 2:
The patent applies different manufacturing parameters to different object sizes locally within the manufacturing system. Small objects receive settings optimized for geometric accuracy, while large objects receive settings optimized for thermal control, thereby addressing the specific needs of each object type without compromise.
2Manufacturing precision
If additive manufacturing settings are optimized for small objects, then geometric accuracy is improved, but thermal-related issues such as under-fusion and warpage worsen for large objects
Solution Approach 1:
The patent divides the manufacturing queue into segments based on object size and applies appropriate settings to each segment. Large objects receive settings that prevent under-fusion and warpage, while small objects receive settings that ensure geometric accuracy, thus resolving the contradiction between precision and thermal control.
Solution Approach 2:
The patent implements local quality control by tailoring manufacturing parameters to the specific size requirements of each object. This ensures that small objects receive precision-optimized settings while large objects receive thermal-stability settings, preventing both under-fusion and maintaining geometric accuracy where needed.
3Manufacturing precision
If different additive manufacturing settings are applied to different object sizes, then quality and geometric accuracy are improved, but manufacturing complexity increases
Solution Approach 1:
The patent changes manufacturing parameters (temperature, speed, power) based on object size categories. By implementing parameter changes rather than completely different processes, the system achieves quality optimization for different object sizes while managing complexity through systematic parameter adjustment rather than process redesign.
Solution Approach 2:
The patent implements dynamic setting adjustment based on object characteristics. The manufacturing system automatically adapts parameters according to object size, providing flexibility and quality optimization without requiring manual intervention or complex reconfiguration, thus managing device complexity while improving precision.
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 enhances the quality and consistency of 3D printed objects by optimizing manufacturing settings based on object-specific characteristics, thereby reducing thermal-related issues and improving geometric accuracy.
Implementation Method 1
Additive manufacturing systems form a three-dimensional (3D) object through the solidification of layers of a build material
Implementation Method 2
The characteristics of a 3D object to be printed affect the environmental conditions experienced during additive manufacturing. Due to the thermal nature of certain additive manufacturing processes, 3D printed objects with larger areas may have higher temperatures than parts of 3D printed objects that have smaller areas.
Data Source
AI summary
In one example in accordance with the present disclosure, a method is described. According to the method, a characteristic of each of multiple three-dimensional (3D) objects to be printed is determined. 3D objects to be printed are grouped based on characteristic similarity. For a group of 3D objects to be printed, an additive manufacturing setting is altered based on the characteristics of the 3D objects to be printed that form the group.