Additive Manufacturing With Close Toolpaths and Nozzle Control
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Solution Overview
Problem
Conventional additive manufacturing methods restrict design freedom and efficiency due to maintaining a predetermined distance of the toolpath, leading to excessive material accumulation and structural inaccuracies.
Innovation Solution
An additive manufacturing method that controls the movement speed and discharge rate of a nozzle to allow closer toolpath trajectories, enabling precise and efficient manufacturing of three-dimensional objects by adjusting movement and discharge rates to prevent excessive material accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the toolpath is maintained at a predetermined distance from itself, then excessive material accumulation is prevented, but design freedom is restricted and manufacturing efficiency decreases
Solution Approach 1:
The patent applies dynamics by making the toolpath distance dynamic rather than static. The controller adjusts the distance between successive toolpath lines based on real-time parameters including material discharge rate, nozzle movement speed, and material properties. This dynamic adjustment allows the system to optimize material deposition in different regions, preventing excessive accumulation while enabling closer toolpath routing for improved manufacturing efficiency and design freedom.
Solution Approach 2:
The patent implements parameter changes by modifying the toolpath distance parameter based on multiple variables. The controller calculates optimal toolpath spacing by considering discharge rate, movement speed, material viscosity, and desired layer thickness. This parameter adaptation enables the system to maintain precision in material accumulation control while allowing tighter toolpath routing to enhance productivity and design flexibility.
2Productivity
If the nozzle moves faster and discharges material faster, then manufacturing efficiency increases, but material accumulation control and structural precision decrease
Solution Approach 1:
The patent applies feedback by implementing a closed-loop control system that continuously monitors material discharge rate and nozzle movement speed. The controller receives feedback on actual material deposition and adjusts toolpath parameters in real-time to maintain precise material distribution. This feedback mechanism allows high-speed manufacturing while preventing excessive material accumulation and maintaining structural precision through dynamic parameter adjustment.
3Adaptability or versatility
If the toolpath is routed closer to itself, then design freedom increases and manufacturing efficiency improves, but excessive material accumulation occurs leading to structural inaccuracies
Solution Approach 1:
The patent implements parameter changes by dynamically adjusting toolpath spacing based on discharge rate and material properties. This allows the system to route toolpaths closer together for improved design freedom and efficiency while compensating for material accumulation through real-time parameter modification, thereby maintaining structural accuracy.
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
Enables efficient and precise manufacturing of three-dimensional objects with reduced structural inaccuracies and increased design freedom by controlling nozzle movement and discharge rates, allowing for features like reinforcing structures and hollow portions.
Implementation Method 1
a curable first material... that can be cured, hardened or set hard so as to form the three-dimensional object
Data Source
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AI summary
An additive manufacturing method for controlling an additive manufacturing system for manufacturing a three-dimensional object from a curable first material according to a three-dimensional data model, the additive manufacturing system, and a three-dimensional object are provided. The nozzle of the additive manufacturing system is moved such that a shortest distance (d23) between a second section (U2) of a target trajectory (T) and a third section (U3) of the target trajectory is less than a thickness (t1) of a first segment (S1) discharged in a first section (U1) of the target trajectory. At least one of a magnitude of a second movement speed, with which the nozzle is moved in the second section, and a magnitude of a third movement speed, with which the nozzle is moved in the third section, is higher than a magnitude of a first movement speed, with which the nozzle is moved in the first section. Alternatively or in addition thereto, at least one of a second discharge rate, with which the first material is discharged from the nozzle in the second section, and a third discharge rate, with which the first material is discharged from the nozzle in the third section, is lower than a first discharge rate, with which the first material is discharged from the nozzle in the first section.