Continuous 3D Toolpaths for Start-Stop-Free Additive Manufacturing
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Solution Overview
Problem
Conventional 3D printing methods, particularly extrusion-based additive manufacturing, face inefficiencies due to the need for frequent starts and stops, which increase print time, create surface blemishes, and weaken material integrity, while spiralized printing methods are limited by fragile structures and inability to handle overhangs or complex geometries.
Innovation Solution
Introducing gaps into 3D models to generate continuous toolpaths, reducing isolated paths and eliminating the need for frequent starts and stops, allowing for continuous printing with improved structural integrity and aesthetic quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional slicing method is used to generate toolpaths, then the printing process can be completed layer by layer, but frequent starts and stops increase print time by up to 10%
Solution Approach 1:
The patent introduces gaps into the 3D model at strategic locations to enable continuous toolpaths that eliminate frequent starts and stops. The gaps allow the extruder to maintain continuous motion and material flow while still printing all necessary layers, thereby maintaining productivity while eliminating time losses from frequent pausing and resuming of the printing process.
2Shape
If conventional slicing method is used, then each layer can be printed separately, but starts and stops create surface blemishes that decrease part aesthetics
Solution Approach 1:
By introducing gaps that enable continuous toolpaths, the invention eliminates the start-stop pattern that creates visible seams and surface blemishes. The continuous motion allows material to be deposited smoothly without interruption, producing superior surface quality and part aesthetics while still completing the print job in a practical timeframe.
3Strength
If conventional slicing method is used, then layer-by-layer printing can be performed, but frequent starts and stops weaken material properties
Solution Approach 1:
The continuous toolpaths enabled by strategic gap placement allow material to be deposited without interruption, ensuring consistent material properties and strength throughout the printed part. The continuous extrusion process prevents weak bonds that occur at start-stop points, while the gaps are positioned to maintain overall structural integrity without requiring excessive print time.
4Productivity
If spiralized printing method is used to eliminate starts and stops, then print time is reduced, but the structures become fragile and cannot handle overhangs or complex geometries
Solution Approach 1:
The patent strategically segments the model by introducing gaps at specific locations rather than using continuous spiralized printing. This segmentation allows the toolpath to remain continuous and maintain structural integrity while still eliminating frequent starts and stops. The gaps are placed to preserve load-bearing paths and support complex geometries like overhangs, unlike spiralized methods that compromise structural strength.
Solution Approach 2:
The invention applies different strategies to different parts of the model by placing gaps selectively at locations that do not compromise structural integrity. Critical load-bearing regions maintain continuous material paths, while non-critical areas incorporate gaps to enable continuous toolpaths. This local differentiation allows the part to handle overhangs and complex geometries while achieving the productivity benefits of continuous printing.
Data Source
AI summary
Toolpath generation for additive manufacturing systems involves operations on polygonal contours derived from a model for additively manufacturing a structure. One aspect involves modifying or creating a model to allow parts to be printed without starting and stopping the printing equipment by generating continuous toolpaths or toolpaths having a reduced number of isolated paths. Another aspect involves modifying a slicing engine to generate a continuous toolpath or toolpath having a reduced number of isolated paths based on a representation of an object to be additively manufactured. Another aspect involves selectively placing the gaps at alternating positions among the sliced layers to create a zippering effect.