Sectioned CAD Slicing for Additive Manufacturing Print Quality
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Solution Overview
Problem
Traditional slicing processes in additive manufacturing are inefficient as they maintain constant print parameters for every layer, failing to optimize different sections of a part, leading to suboptimal manufacturing efficiency and quality.
Innovation Solution
A slicing process that divides a CAD model into sections with unique print parameters for each, allowing for variable printing parameters across different areas of the part, optimizing the printing process by adjusting section positions and layering to enhance fusion and integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If constant print parameters are maintained for every layer, then the slicing process is simple, but manufacturing precision and quality are suboptimal
Solution Approach 1:
The patent segments the part into multiple sections, each with its own optimized print parameters. The slicing process divides the model into sections based on geometric features, orientation, or material requirements, allowing different print parameters (such as layer height, infill density, print speed, and temperature) to be applied to different sections. This segmentation enables precision optimization for each section while maintaining overall process manageability.
Solution Approach 2:
The patent implements local quality by assigning unique print parameters to different sections of the part. Each section can have customized parameters tailored to its specific requirements - for example, critical features may use higher precision settings while non-critical areas use faster, lower-resolution settings. This local optimization improves overall manufacturing precision without uniformly increasing complexity across the entire part.
2Productivity
If variable print parameters are used for different sections, then manufacturing efficiency is improved, but device complexity increases
Solution Approach 1:
The slicing process automatically segments the model into sections that can be printed with optimized parameters for each region. This segmentation enables parallel processing of different sections with appropriate parameters, improving overall productivity by reducing total print time while managing complexity through automated section identification and parameter assignment.
Solution Approach 2:
The patent applies parameter changes by varying print parameters across different sections - such as adjusting layer height, infill patterns, print speed, and temperature based on local requirements. This enables faster printing for non-critical sections while maintaining high quality for critical features, thereby improving manufacturing efficiency without requiring complete reconfiguration of the entire printing process.
3Productivity
If traditional slicing with constant parameters is used, then device complexity is low, but productivity is reduced
Solution Approach 1:
The patent introduces dynamics into the slicing process by making print parameters variable rather than static. The system dynamically assigns different parameters to different sections based on their characteristics, allowing the printing process to adapt to local requirements. This dynamic approach improves productivity by optimizing print speed and quality for each section while managing complexity through automated parameter selection algorithms.
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 enables more efficient and optimized additive manufacturing by allowing for customized print parameters per section, improving the quality and speed of producing complex components.
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 softened thermoplastic material, 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 plurality of sections to manufacture the part.