Section-Based 3D Printing Parameters for Large Complex Parts
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Solution Overview
Problem
Traditional 3D printing methods using molten thermoplastic materials are inefficient for manufacturing large or complex parts due to constant print parameters across all layers, which limits optimization and increases production time.
Innovation Solution
The method involves dividing a CAD model into sections with unique print parameters for each layer, allowing for varying print parameters across different sections of a part, enabling optimized layer-by-layer printing and improved fusion of sections during the additive manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If constant print parameters are used across all layers in traditional 3D printing, then the printing process is simple to control, but production time increases and efficiency decreases for large or complex parts
Solution Approach 1:
The patent divides the printing process into multiple zones with different print parameters. Each zone can have independently optimized parameters such as temperature, speed, and layer height based on the specific requirements of different parts of the component, enabling parallel optimization across multiple regions simultaneously
Solution Approach 2:
The system dynamically adjusts print parameters during the manufacturing process by transitioning between different parameter zones. The printer can change temperature, extrusion rate, and other parameters on-the-fly as it moves from one zone to another, optimizing each section for its specific requirements rather than using fixed parameters throughout
2Manufacturing precision
If molten thermoplastic material is used for 3D printing, then material fusion between layers is achieved, but the printing process becomes too slow for manufacturing large items
Solution Approach 1:
The patent changes material parameters by transitioning from molten thermoplastic to powder-based materials that can be applied and fused more rapidly. By adjusting parameters such as particle size, binding agent composition, and fusion temperature, the system achieves both high-speed deposition and adequate layer bonding for large-scale manufacturing
Solution Approach 2:
The system utilizes phase transitions in the material lifecycle - materials are deposited in one phase (such as powder or semi-solid) and then transition to a bonded state through controlled fusion or curing processes. This separates the deposition speed from the fusion quality, allowing rapid material application followed by optimized bonding
3Productivity
If near-net-shape printing with larger beads is used, then printing speed increases, but additional machining time is required to trim parts to final size
Solution Approach 1:
The patent applies different print parameters to different zones of the part, with higher precision parameters (smaller beads, slower deposition) applied to critical surfaces that require tight tolerances, and faster parameters (larger beads, higher speed) applied to non-critical areas. This eliminates the need for extensive post-machining while maintaining accuracy where needed
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 enhances the efficiency and accuracy of the 3D printing process by optimizing print parameters for different sections of a part, reducing production time and improving the quality of the final product by allowing for distinct print parameters across layers.
Implementation Method 1
melting a thin layer of thermoplastic material, and applying this material in layers to produce a final part
Implementation Method 2
Friction from the rotating screw, combined with heat from the barrel may soften the thermoplastic material
Implementation Method 3
heat from the barrel may soften the thermoplastic material
Implementation Method 4
Forced under pressure through a small round opening in a die that is attached to the front of the extruder barrel
Implementation Method 5
The melted thermoplastic material may be applied to the existing structure in layers, melting and fusing with the existing material
Data Source
AI summary
A method of forming a part using additive manufacturing may include receiving, at a computer numeric controlled (CNC) machine, a computer aided design (CAD) model of the part. The method may further include dividing the CAD model into plurality of sections. The method may further include slicing each of the plurality of sections into a plurality of layers. Each section may include a distinct set of print parameters. The method may further include depositing a flowable material onto a worktable according the set of print parameters for each section of the of the plurality of sections to manufacture the part.