Build Orientation Optimization for Low-Distortion Additive Manufacturing
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Solution Overview
Problem
Conventional methods for determining build orientation in additive manufacturing to minimize thermal distortion are time-consuming, inaccurate, and inefficient in terms of computational resources.
Innovation Solution
An algorithm using a momentum of inertia based objective function to determine the optimal build orientation, where the output of the function serves as a proxy for thermal distortion, allowing for rapid calculation of orientations that minimize thermal distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional methods are used to predict actual thermal distortion before the build, then measurement precision is improved, but calculation time and productivity deteriorate
Solution Approach 1:
The patent changes the parameter being optimized from actual thermal distortion calculation to moment of inertia calculation. By transforming the objective function to use moment of inertia as a proxy metric, the system achieves comparable orientation optimization results with significantly reduced computational time, as moment of inertia calculations are mathematically simpler and faster than thermal distortion predictions.
Solution Approach 2:
The patent introduces moment of inertia as an intermediary parameter that mediates between build orientation and thermal distortion. Instead of directly calculating thermal distortion for each orientation, the system uses moment of inertia as a surrogate metric that correlates with thermal distortion behavior, enabling faster optimization while maintaining practical accuracy.
2Manufacturing precision
If conventional methods are used to predict actual thermal distortion before the build, then manufacturing precision is improved, but computational resource efficiency deteriorates
Solution Approach 1:
The patent changes the computational parameter from complex thermal distortion prediction to simpler moment of inertia calculation. This parameter substitution maintains the ability to control thermal distortion by optimizing build orientation, while dramatically improving computational resource efficiency and processing speed.
Solution Approach 2:
The patent extracts the essential geometric property (moment of inertia) from the complex thermal analysis process. By taking out only the necessary geometric moment of inertia calculation rather than performing full thermal distortion prediction, the system achieves orientation optimization with improved resource efficiency while retaining sufficient precision for manufacturing.
3Measurement precision
If full thermal distortion calculation is performed for each orientation, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent simplifies the algorithm by changing the measured parameter from thermal distortion to moment of inertia. This parameter transformation reduces algorithmic complexity from complex thermal field calculations to straightforward mechanical property calculations, making the system less complex while maintaining practical measurement precision for orientation optimization.
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
The method significantly reduces calculation time and resource consumption while accurately determining build orientations that minimize thermal distortion, achieving optimal results in less than 0.05 seconds per iteration.
Implementation Method 1
The algorithm includes a momentum of inertia based objective function, wherein the output (a numerical value) of the objective function can be used as a proxy for thermal distortion
Data Source
AI summary
Embodiments of the systems and methods disclosed herein can related to an additive manufacturing process involving the use of an algorithm to determine the optimal build orientation of a build that will result in minimal thermal distortion during the build. The algorithm includes a momentum of inertia based objective function, wherein the output of the objective function can be used as a proxy for thermal distortion. In some embodiments, objective function can be configured as a mathematical matrix with mathematical variables modeling rotation angles of a build. The rotation angles can be in the x-, y-, and/or z-geometric planes of the build with respect to the build plate. An objective function output can be calculated for each iterative rotation. The minimum objective function output can be used as the rotation representing the orientation that would result in minimal thermal distortion.