Variable Boundary Shells for Dense Additive Manufacturing
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Solution Overview
Problem
In additive manufacturing, densely packing objects in a common build process can lead to reduced object quality due to thermal diffusion and interference between objects, causing overheating and impaired mechanical or appearance properties, and defining a manufacturing boundary object shell is complex and resource-intensive.
Innovation Solution
A method involving a computer-implemented process to determine a manufacturing boundary object shell based on a property diffusion model, which predicts the thermal or other property diffusion from an object, allowing for the definition of a variable thickness shell that prevents adverse effects on neighboring objects, thereby optimizing object placement and density within the fabrication chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If objects are densely packed in a common build process, then productivity increases, but object quality deteriorates due to thermal diffusion and interference
Solution Approach 1:
The patent applies preliminary action by calculating and establishing manufacturing boundary object shells around each object before the actual build process. These shells define exclusion zones that prevent thermal interference, allowing dense packing while maintaining quality. The shells are determined based on property diffusion models that predict thermal behavior during manufacturing.
2Manufacturing precision
If a manufacturing boundary object shell is defined to prevent thermal interference, then object quality is maintained, but device complexity increases
Solution Approach 1:
The patent uses copying by creating simplified boundary representations (shells) that replicate the essential thermal influence zones of objects. Instead of modeling complex thermal diffusion in real-time, the system creates pre-defined shell copies that approximate the thermal boundary, reducing computational complexity while maintaining accuracy.
3Manufacturing precision
If a variable thickness shell is used to optimize spacing, then manufacturing precision improves, but calculation complexity increases
Solution Approach 1:
The patent applies local quality by making the shell thickness variable rather than uniform. The shell thickness is adjusted locally based on the specific thermal properties and geometry of each object, providing optimal spacing where needed while reducing constraints elsewhere. This allows precise control over thermal interference zones.
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 enables efficient and high-quality production of multiple objects by maintaining sufficient spacing and minimizing thermal interference, ensuring that objects meet quality specifications while maximizing the use of available manufacturing volume.
Implementation Method 1
predicts the thermal or other property diffusion from an object, allowing for the definition of a variable thickness shell that prevents adverse effects on neighboring objects
Data Source
AI summary
In an example, a method includes receiving, at a processor, object model data representing at least a portion of an object to be generated by an additive manufacturing apparatus by fusing build material. Using a processor and from the object model data, a property diffusion model for the object in object generation may be determined. Using a processor and based on the property diffusion model, a manufacturing boundary object shell around the object and encompassing an external volume may be determined. The shell may have a variable thickness determined so as to include build material for which, in generation of the object, the property modelled in the property diffusion model has a value which is predicted to conform to a predetermined parameter.