Additive Manufacturing Task Scheduling for Constant Layer Timing

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Solution Overview

Problem

In additive manufacturing, variations in layer processing times can lead to unintended local heat fluctuations and mechanical defects due to inconsistent heating profiles, which are difficult to manage with existing techniques.

Innovation Solution

Implementing a predetermined constant or approximately constant layer processing time for all layers, using a processor to schedule ancillary tasks within this time frame, and employing an agent distributor to selectively apply fusing and detailing agents, ensuring consistent layer formation and minimizing inactive periods for apparatus components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If layer processing time varies between layers, then the system can accommodate different task durations, but unintended local heat fluctuations and mechanical defects occur

Engineering Contradiction:

Improvetask duration flexibilityVSAvoidlayer formation consistency

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The system dynamically adjusts task scheduling and apparatus component operation to maintain constant layer processing time. The processor coordinates ancillary tasks and component operations to ensure each layer completes within the predetermined time frame, adapting task execution to maintain temporal consistency across varying layer complexities.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the time parameter from variable to constant by implementing a predetermined layer processing time for all layers. This parameter change ensures uniform heating profiles and consistent layer formation, preventing heat fluctuations and mechanical defects while maintaining manufacturing precision.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If ancillary tasks are performed outside layer processing time, then task completion is possible, but inactive periods increase and productivity decreases

Engineering Contradiction:

Improvetask completion capabilityVSAvoidlayer processing efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The system eliminates idle or inactive periods by continuously utilizing apparatus components during layer processing time. Ancillary tasks are scheduled to execute within the predetermined time frame, ensuring continuous productive operation without interruptions or wasted time, thereby maximizing layer processing efficiency.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system performs ancillary tasks in advance or during layer processing time rather than after. By scheduling and executing maintenance, calibration, and preparation tasks within the predetermined layer processing time, the system ensures task completion while maintaining continuous productivity and eliminating post-processing idle periods.

Inventive Principle:

Principle #10Preliminary action

3Speed

If heating profiles are inconsistent between layers, then processing speed can be increased, but mechanical defects increase

Engineering Contradiction:

Improveprocessing speedVSAvoidmechanical defect rate

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The system applies periodic heating at consistent intervals for each layer, with each layer receiving the same heating profile within the predetermined time frame. This periodic consistency ensures uniform thermal treatment across all layers, preventing mechanical defects while maintaining high processing speed through optimized heating cycles.

Inventive Principle:

Principle #19Periodic action

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 ensures consistent layer formation, reduces mechanical defects, and maintains a stable processing environment by synchronizing ancillary tasks with layer processing, thereby enhancing the quality and consistency of the three-dimensional objects produced.

Implementation Method 1

an agent distributor to selectively apply fusing and detailing agents

Methodology Applied

Scientific EffectSelective distribution:

Implementation Method 2

a solidification method may include heating the layers of build material to cause melting in selected regions

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

Implementing a predetermined constant or approximately constant layer processing time for all layers, using a processor to schedule ancillary tasks within this time frame

Methodology Applied

Scientific EffectTime synchronization:

Data Source

PatentUS11235531B2Selecting a task in additive manufacturing

Publication Date: 2022.02.01 PERIDOT PRINT LLC

AI summary

In an example, a method of controlling an additive manufacturing apparatus to generate a three dimensional object comprises processing successive layers of build material so as to form successive layers of a three dimensional object, wherein the processing of each layer is performed within a predetermined layer processing time by a plurality of components. The method may further include selecting, by at least one processor, from a plurality of ancillary tasks, at least one ancillary task to be performed in relation to at least one component of the plurality of components. The method may further include scheduling, by at least one processor, the at least one ancillary task to be performed in relation to the at least one component within the predetermined layer processing time for a single layer or for multiple layers of the build material.