Sectioned Additive Manufacturing for Layer-Specific Print Control
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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 print model into multiple sections, where each section can have its own unique print parameters. This segmentation allows different regions of the part to be printed with optimized parameters specific to their requirements, thereby reducing overall production time without requiring complete system complexity
Solution Approach 2:
The patent implements local quality by allowing each section of the print model to have distinct print parameters tailored to its specific requirements. This enables optimization of printing speed, temperature, and other parameters for different regions, improving overall productivity while maintaining control
2Productivity
If unique print parameters are assigned to each section for optimized printing, then production time is reduced and efficiency improves, but the complexity of managing print parameters increases
Solution Approach 1:
By segmenting the print model into distinct sections, the patent enables independent parameter optimization for each section. This segmentation strategy improves printing efficiency by allowing parallel processing and localized optimization, while the modular structure helps manage parameter complexity
3Manufacturing precision
If traditional layer-by-layer printing with uniform parameters is used, then the printing process is straightforward, but manufacturing precision and quality optimization are limited
Solution Approach 1:
The patent applies local quality by assigning unique print parameters to each section, enabling precise control over printing quality in different regions. This allows critical areas to receive optimized parameters for higher precision while less critical areas use standard parameters, overall improving manufacturing precision without excessive complexity
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
Implementation Method 2
Friction from the rotating screw, combined with heat from the barrel may soften the thermoplastic material
Implementation Method 3
Friction from the rotating screw, combined with heat from the barrel may soften the thermoplastic material
Implementation Method 4
which may then be forced under pressure through a small round opening in a die
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.