Dynamic Toolpath Adjustment for Random Reinforcement in Additive Manufacturing

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Solution Overview

Problem

Existing additive manufacturing processes rely on predetermined toolpaths that assume random reinforcement material distribution, leading to inefficient use of reinforcement materials and potential weaknesses in the final product, as they do not account for the actual arrangement of reinforcement materials during the manufacturing process.

Innovation Solution

A method and system that dynamically determine the toolpath based on the actual arrangement of reinforcement materials on the fabrication bed, allowing for real-time adjustment of the toolpath to structurally incorporate reinforcement materials and minimize material usage, thereby optimizing the distribution of reinforcement materials within the object.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If reinforcement material is randomly distributed in the fabrication bed, then the manufacturing process is simpler, but the structural strength and reliability of the final product deteriorate due to unpredictable reinforcement arrangement

Engineering Contradiction:

Improvesimplicity of manufacturing processVSAvoidstructural strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent applies dynamics by transitioning from a static, predetermined toolpath to a dynamic toolpath that adapts in real-time based on the actual reinforcement material distribution. The system captures images of the fabrication bed, processes the reinforcement arrangement, and dynamically adjusts the toolpath during manufacturing to optimize structural strength while maintaining process simplicity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent implements feedback by using image capture and processing systems to detect the actual arrangement of reinforcement materials during manufacturing. This information feeds back into the control system, which then adjusts the toolpath in real-time to account for the actual reinforcement distribution, ensuring optimal structural outcomes.

Inventive Principle:

Principle #23Feedback

2Productivity

If a predetermined toolpath is used based on average reinforcement distribution, then the manufacturing process is faster and simpler, but the manufacturing precision and optimization of reinforcement utilization deteriorate

Engineering Contradiction:

Improvemanufacturing speedVSAvoidprecision of reinforcement incorporation

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by capturing images and processing the reinforcement material arrangement before the tool executes the activation process. This allows the system to plan and determine the optimal toolpath in advance based on the actual reinforcement distribution, ensuring precise reinforcement incorporation while maintaining manufacturing efficiency.

Inventive Principle:

Principle #10Preliminary action

3Strength

If controlled path deposition of reinforcement material is used, then the structural strength and reinforcement distribution are improved, but the device complexity and manufacturing time increase

Engineering Contradiction:

Improvestructural strengthVSAvoidcomplexity of reinforcement deposition system

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent applies inversion by reversing the traditional approach: instead of controlling the reinforcement material deposition path to achieve optimal strength, the system randomly deposits reinforcement materials and then controls the toolpath to adapt to the actual arrangement. This inverts the control from deposition to activation, simplifying the device while maintaining structural strength.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS11472122B2Fabrication of composite parts by additive manufacturing and microstructure topology customization

Publication Date: 2022.10.18 SAUDI ARABIAN OIL CO

AI summary

A system and method for optimizing an additive manufacturing process in which a reinforcement material is randomly introduced to a fabrication bed. An image of the fabrication bed is captured. The image is analyzed by code in a computer to identify the actual arrangement of the randomly deposited reinforcement material relative to the object being manufactured. Based on the image data showing the reinforcement material, a toolpath is dynamically determined that incorporates the random reinforcement material. Accordingly, the toolpath incorporates the reinforcement material into the structure of the object, which can result in a reduction of the total amount of raw material is fused to create the object being manufactured.