Additive Manufacturing Tool Paths for Intersecting Fiber Networks
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Solution Overview
Problem
Current additive manufacturing systems face challenges in efficiently determining optimal tool paths for structures with complex geometries and intersecting elongate elements, which affects the accuracy and strength of the final product.
Innovation Solution
A method and system that utilize a graph structure to represent intersecting elongate elements, determine regions, and generate tool paths for each region, allowing for precise control of the additive manufacturing process, especially with continuous reinforcements like fibers and curable matrices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional additive manufacturing methods are used to manufacture structures with complex geometries and intersecting elongate elements, then the manufacturing process can be completed, but the manufacturing precision and structural strength are insufficient
Solution Approach 1:
The patent segments the complex structure into multiple regions based on a graph representation where nodes represent intersecting elongate elements and edges represent connections between them. This segmentation allows the manufacturing system to process each region independently with optimized tool paths, improving precision while managing complexity through systematic division of the manufacturing task.
Solution Approach 2:
The patent introduces a graph-based abstract representation layer between the physical structure and the manufacturing process. By transforming the 3D geometric complexity into a 2D graph structure with nodes and edges, the system can determine optimal tool paths more accurately, resolving the contradiction between handling complex geometries and achieving manufacturing precision.
2Productivity
If traditional tool path generation methods are used, then the manufacturing process can proceed, but the fabrication time is excessive and productivity is low
Solution Approach 1:
The patent performs preliminary analysis by constructing a graph structure representing all intersecting elongate elements and their relationships before generating tool paths. This preliminary action identifies optimal manufacturing sequences and regions, enabling faster fabrication by avoiding redundant movements and operations during the actual manufacturing process.
Solution Approach 2:
The patent dynamically determines tool paths based on the graph structure representation of the structure's geometry. Rather than using fixed or predetermined paths, the system adapts tool path generation to the specific configuration of intersecting elements, optimizing fabrication speed while maintaining precision for each unique geometric arrangement.
3Strength
If continuous reinforcements like fibers are embedded within the material, then the structural strength is multiplied, but the difficulty of detecting and measuring the correct tool paths increases
Solution Approach 1:
The patent introduces a graph structure as an intermediary representation between the physical structure with continuous reinforcements and the tool path generation process. The graph nodes represent intersecting elongate elements and edges represent their connections, providing a simplified abstract model that captures the essential geometric relationships needed for tool path determination without the full complexity of the 3D reinforced structure.
Data Source
AI summary
Methods and associated systems and apparatus are disclosed for determining a tool path for use in additively manufacturing a structure. The methods may include receiving data that at least partially defines a plurality of intersecting elongate elements forming a layer of the structure, and determining, based on the received data, a graph structure comprising a plurality of edges each representing one of the plurality of intersecting elongate elements, and a node representing an intersection of at least two of the plurality of intersecting elongate elements. The method may also include determining a plurality of regions of the structure based on the graph structure, each region comprising one or more elongate elements, and generating a plurality of tool paths for each of the plurality of regions.