Concurrent 3D Printing of Parts With Dissimilar Slice Heights
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Solution Overview
Problem
Current 3D printing systems are limited in throughput as they require identical layer heights for all parts on the build substrate, restricting the ability to concurrently print multiple parts with varying slice heights.
Innovation Solution
A method and system that sequences layers based on the lowest Z height of each part, allowing a shared platen to move in the Z direction to accommodate parts with varying slice heights, and adjusts extrusion flow rate or print head speed to control layer thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If identical layer heights are required for all parts on the build substrate, then manufacturing precision is maintained, but productivity is limited due to restricted concurrent printing capability
Solution Approach 1:
The system dynamically adjusts the platen position in the Z direction based on the varying slice heights of different parts. The platen moves to different Z levels to accommodate parts with different layer heights, allowing concurrent printing of multiple parts with dissimilar slice heights while maintaining consistent extrusion parameters and material properties throughout the printing process.
2Productivity
If a shared platen is used to print multiple parts with varying slice heights, then productivity increases, but device complexity increases due to coordinated movement requirements
Solution Approach 1:
The system segments the printing process into discrete Z-level positions corresponding to different platen locations. Each part is assigned to specific Z-levels based on its slice height requirements, and the platen is positioned accordingly. This segmentation allows independent control of each part's printing layer while using a single shared platen, reducing the need for complex multi-platen coordination systems.
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
Enables concurrent printing of multiple parts with different layer heights, enhancing throughput and minimizing variations in part quality by using the same material under consistent process conditions.
Implementation Method 1
a part may be printed from a digital representation of the printed part by extruding a viscous, flowable thermoplastic or filled thermoplastic material from a print head along toolpaths at a controlled extrusion rate
Implementation Method 2
The print head includes a liquefier which receives a supply of the thermoplastic material in the form of a flexible filament, and a nozzle tip for dispensing molten material. A filament drive mechanism engages the filament such as with a drive wheel and a bearing surface, or pair of toothed-wheels, and feeds the filament into the liquefier where the filament is heated to a molten pool
Implementation Method 3
The extruded flow of material is deposited as a sequence of roads onto a substrate, where it fuses to previously deposited material and solidifies upon a drop in temperature
Implementation Method 4
positioning the digital representation of parts on a build platform of the 3D printer... indexing a Z height between the sequenced layers
Data Source
AI summary
A method of printing a plurality of parts with varying layer heights in a single print job in a 3D printer includes providing a plurality of sliced 3D digital representations of a plurality of parts with varying slice heights in the Z direction, positioning the digital representation of parts on a build platform of the 3D printer and determining a printing sequence of the layers of the parts based upon a lowest Z height between the plurality of sliced 3D digital representations. The method further includes extruding the layers of the plurality of disjoined parts with one or more print heads based upon the determined printing sequence and intermittently indexing z height between the sequenced layers until each of the plurality of parts is printed.