Sectioned Additive Manufacturing for Faster Large-Part Printing
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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 and layers, allowing for varied print parameters across different sections, enabling optimized printing by adjusting the position and interweaving of sections to enhance fusion and reduce production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If constant print parameters are used across all layers in traditional 3D printing, then the printing process is simple to operate, but the production time increases and manufacturing efficiency decreases
Solution Approach 1:
The patent divides the printing process into multiple sections, each with its own optimized print parameters. The system segments the build volume into different zones (first section and second section) that can be printed simultaneously with different parameters, allowing optimization of each section while maintaining overall process manageability
Solution Approach 2:
The patent implements dynamic parameter adjustment by allowing print parameters to vary across different sections and layers. The system can dynamically change parameters such as temperature, print speed, and bead width for different sections, transforming the static constant-parameter approach into a dynamic adaptive process that improves efficiency
2Device complexity
If constant print parameters are used across all layers, then the control process is simple, but the fusion of layers is insufficient and part quality decreases
Solution Approach 1:
The patent applies local quality optimization by assigning different print parameters to different sections based on their specific requirements. Each section can have customized parameters for temperature, speed, and bead dimensions, ensuring optimal layer fusion and part quality for each local region rather than using a one-size-fits-all approach
3Ease of operation
If traditional single-section printing is used, then the equipment operation is simple, but the production time for large or complex parts is excessive
Solution Approach 1:
The patent divides the printing task into multiple sections that can be printed simultaneously. The system creates a first section and a second section from the same build volume, allowing parallel printing operations that significantly reduce production time for large or complex parts while maintaining operational simplicity through automated section management
Solution Approach 2:
The patent enables continuous productive action by printing multiple sections simultaneously without idle time. The system coordinates the printing of different sections in parallel, ensuring that the printer is continuously productive throughout the build process rather than sequentially processing each section
4Productivity
If larger bead size is used to speed up printing, then the printing speed increases, but the manufacturing precision and detail quality decrease
Solution Approach 1:
The patent allows different bead sizes and print parameters for different sections. Critical detail areas can use smaller beads for high precision, while non-critical areas use larger beads for faster printing. This local optimization enables the system to achieve both speed and quality where needed without compromise
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 allows for the efficient manufacturing of complex parts by optimizing print parameters for each section, improving the fusion of layers and reducing the overall production time, enabling the creation of larger and more intricate designs.
Implementation Method 1
melting a thin layer of thermoplastic material, and applying this material in layers
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
the extruded string of material may be cooled and coiled up for use in a 3D printer
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.