3D Print Build Orientation to Minimize Support Structures
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Solution Overview
Problem
Additive manufacturing techniques face challenges in fabricating complex parts with downfacing areas due to the need for support structures, which increase material usage, manufacturing time, and waste, especially when combined with topology optimization, as these structures can be laborious to remove and may deteriorate the surface quality.
Innovation Solution
A method for optimizing build orientation in additive manufacturing systems, using a 3D printing system with a print head and build plate, to minimize the requirement for support structures by identifying an optimized build orientation based on physical and design constraints, such as critical surface slope angles, to reduce the amount of support structures needed during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If support structures are used to manufacture parts with downfacing areas, then the part can be successfully fabricated, but material usage increases and manufacturing time increases
Solution Approach 1:
The patent applies preliminary action by performing build orientation optimization before the actual additive manufacturing process. The system evaluates multiple build orientations and selects the optimal one that minimizes support structure requirements while ensuring successful fabrication of downfacing areas. This preliminary optimization prevents excessive material waste and manufacturing time consumption during the actual printing process.
2Reliability
If support structures are used to manufacture parts with downfacing areas, then the part can be successfully fabricated, but manufacturing time increases
Solution Approach 1:
The system performs build orientation optimization as a preliminary step before manufacturing. By evaluating and selecting the optimal build orientation in advance, the system minimizes the amount of support structures required, which directly reduces manufacturing time while ensuring successful fabrication of complex geometries with downfacing areas.
3Reliability
If support structures are used to manufacture parts with downfacing areas, then the part can be successfully fabricated, but surface quality deteriorates
Solution Approach 1:
The patent applies preliminary action by optimizing build orientation before manufacturing to minimize support structure requirements. By selecting the optimal build orientation that reduces the extent of downfacing areas requiring support structures, the system preserves surface quality while still enabling successful fabrication of complex geometries.
4Loss of substance
If build orientation is optimized to minimize support structures, then material waste is reduced, but computational complexity increases
Solution Approach 1:
The system applies self-service by implementing an automated build orientation optimization process that evaluates multiple orientations and automatically selects the optimal one. This self-service approach minimizes manual intervention and computational overhead while achieving the goal of reducing material waste through support structure minimization.
Data Source
AI summary
In accordance with some embodiments, systems, methods, and media for controlling support structures and build orientation are provided. In some embodiments, a method for additive manufacturing a part using a three dimensional (3D) printing system, the 3D printing system including a print head and a build plate is provided, the method comprising: receiving a plurality of physical constraints associated with the part; optimizing a build orientation of the part to identify an optimized build orientation b* for the part with respect to a design domain defined by the physical constraints based on the plurality of physical constraints, and a plurality of design constraints using at least one variable associated with build orientation as an optimization variable, the plurality of design constraints comprising: an initial build orientation b0; and a critical surface slope angle and generating a part model based on the optimized build orientation b*.