Additive Manufacturing Tool Paths From Lines and Surfaces
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Solution Overview
Problem
Existing processes for generating tool path data in additive manufacturing are computationally intensive, fail to utilize the full resolution of the manufacturing apparatus, and often produce objects with inferior material and structural properties compared to traditional methods.
Innovation Solution
A method that generates tool path data by discretizing lines or surfaces to create layer points and projecting them onto build layers, allowing for the direct creation of tool paths without generating closed contours from volumetric representations, thus reducing computational intensity and improving resolution and implementation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing processes generate tool path data from volumetric representations with closed contours, then complete object coverage is achieved, but computational intensity increases significantly
Solution Approach 1:
The invention segments the tool path generation process by treating each layer independently and using projection to connect layers, avoiding the need to process the entire volumetric representation at once. This reduces computational complexity while maintaining accuracy.
Solution Approach 2:
The invention transitions from 3D volumetric processing to 2D layer-based processing with projection operations. By working in 2D slices and projecting points between layers, the computational burden is significantly reduced while maintaining the ability to represent complex 3D geometries.
2Manufacturing precision
If existing processes use standard slicing methods, then all build layers are covered, but the full resolution of the additive manufacturing apparatus is not utilized
Solution Approach 1:
The invention performs preliminary discretization of lines and surfaces before slicing, creating a refined point cloud that captures the full resolution of the apparatus. This pre-processing step ensures that the subsequent slicing and projection operations can utilize the maximum resolution capability of the manufacturing equipment.
3Manufacturing precision
If existing processes generate detailed tool path data, then object detail is improved, but implementation time increases
Solution Approach 1:
The invention replaces the traditional mechanical slicing and contour generation process with a projection-based mathematical approach. By projecting discretized points directly from one layer to another, the method eliminates complex geometric calculations and reduces implementation time while maintaining detailed object representation.
Data Source
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AI summary
Generating tool path data for use in additive manufacturing comprises providing object design data in which at least part of the object is represented abstractly using lines and/or surfaces (212). The lines and/or surfaces can then be used to provide tool path data for the build layers of an additive manufacturing apparatus (214). The tool paths can be reconfigured to reduce the overall distance travelled and/or travel time when the additive manufacturing apparatus implements the tool path data. An additive manufacturing parameter for a structural feature of the object can also be selected based on the geometry of the structural feature and specified in the tool path data (208).