Additive Manufacturing Scan Path Control With Curve-Based Build Files
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Solution Overview
Problem
Existing additive manufacturing systems face increased processing time and memory requirements when handling complex three-dimensional components, leading to higher production costs and reduced precision due to the need for large electronic files containing multiple linear sections and extensive memory-intensive rendering processes.
Innovation Solution
A controller for additive manufacturing systems that generates control signals to direct a consolidation device along scan paths based on the component's outer perimeter, generating function, and generating function constants, reducing the need for extensive memory and processing power by using a build file with fewer data requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electronic files contain a plurality of linear sections to approximate complex three-dimensional components, then the precision of component representation is improved, but the file size increases and processing time increases
Solution Approach 1:
The patent applies mathematical curves (B-splines, NURBS) to represent component geometry instead of linear sections. This curvature-based approach accurately represents complex three-dimensional shapes with fewer mathematical definitions, reducing file size and processing time while maintaining or improving precision compared to linear approximation methods.
Solution Approach 2:
The patent changes the fundamental parameters used to define geometry from coordinate-based linear sections to mathematical curve parameters (control points, knot vectors, basis functions). This parameter transformation allows compact representation of complex surfaces and curves, significantly reducing data volume while preserving geometric fidelity.
2Manufacturing precision
If electronic files contain a plurality of linear sections to approximate complex three-dimensional components, then the precision of component representation is improved, but the file size increases
Solution Approach 1:
The patent uses mathematical curves to represent geometry, which can describe complex shapes with far fewer data points than linear sections. A single mathematical curve definition can replace thousands of linear coordinate points, dramatically reducing file size while accurately representing the component geometry.
Solution Approach 2:
The patent uses mathematical models (B-splines, NURBS) as abstract representations of the physical component geometry. These mathematical copies can be stored compactly and then used to generate manufacturing data, reducing the need to store large amounts of detailed coordinate information while preserving geometric accuracy.
3Ease of operation
If rendering is performed to create a three-dimensional image of the component, then visualization is improved, but memory requirements increase and processing slows down
Solution Approach 1:
The patent represents three-dimensional surfaces using mathematical curves and surfaces (NURBS, B-splines) that can be evaluated on-demand. Instead of storing and rendering large meshes that consume significant memory, the system stores compact mathematical definitions that can be rendered efficiently when needed, reducing memory requirements while maintaining visualization quality.
4Ease of operation
If extensive rendering is performed to create three-dimensional images, then visualization quality is improved, but production cost increases
Solution Approach 1:
The patent uses mathematical surface representations that are computationally efficient to render compared to detailed mesh models. This approach maintains high visualization quality while reducing the computational resources and time required for rendering, thereby lowering production costs associated with software processing and system requirements.
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 reduces memory and processing requirements, increases precision, and decreases production costs by enabling the fabrication of complex components with fewer errors and improved rendering efficiency.
Implementation Method 1
a focused energy source configured to generate at least one beam that moves along the surface to heat the particulate to a melting point creating a melt path
Data Source
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AI summary
A controller (106) for use in an additive manufacturing system (100) including a consolidation device (138) configured to consolidate material (109) is provided. The controller (106) is configured to receive a build file for a component (104, 200) including a plurality of build layers (116), wherein each build layer (116) includes a component outer perimeter (202), at least one build layer (116) generating function, at least one generating function variable, and at least one generating function constant. The controller (106) is configured to generate at least one control signal to control a power output throughout at least one scan path (152) of the consolidation device (138) across the material (109) for each build layer (116) of the plurality of build layers (116), the at least one scan path (152) generated based at least partially on the component (104, 200) outer perimeter (202), the at least one generating function, the at least one generating function variable, and the at least one generating function constant for each build layer (116).