3D Printer Extrusion Speed Control for Local Print Quality
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Solution Overview
Problem
Existing 3D printing methods do not adequately account for the impact of extrusion speed on localized part quality, leading to suboptimal printing conditions.
Innovation Solution
A process and system that automatically adjusts print speed and quality by calculating an optimized X-Y velocity of the print head based on a scaling factor, considering nozzle size, filament material properties, and user preferences, and modifying the computer numerical control code to balance speed and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the print head velocity is increased to improve productivity, then the extrusion speed increases, but the localized part quality deteriorates
Solution Approach 1:
The patent implements dynamic adjustment of print head velocity by modifying G-code instructions based on calculated optimal speeds. The system transitions from static velocity commands to dynamic velocity profiles that adapt to local geometric features, allowing speed optimization without sacrificing quality in critical areas.
Solution Approach 2:
The patent applies different velocity optimizations to different regions of the print path based on local geometry. By analyzing chord segments and calculating optimal velocities for each segment, the system ensures high quality where needed while maintaining high speed in less critical areas, resolving the contradiction between overall productivity and localized quality.
2Loss of time
If the extrusion speed is increased to reduce printing time, then the production efficiency improves, but the surface finish quality deteriorates
Solution Approach 1:
The patent changes the velocity parameter dynamically along the print path based on geometric analysis. By calculating optimal velocities for different chord segments and applying these variations, the system reduces total printing time while maintaining surface finish quality through appropriate speed selection in different regions.
Solution Approach 2:
The patent performs preliminary analysis of the toolpath geometry and pre-calculates optimal velocity profiles before printing. This advance preparation allows the system to execute prints at optimized speeds without real-time adjustments, reducing printing time while ensuring quality is maintained through pre-planned velocity variations.
3Ease of operation
If a fixed print speed is used to simplify the printing process, then the ease of operation is improved, but the balance between speed and quality deteriorates
Solution Approach 1:
The patent implements self-service by having the system automatically analyze its own toolpath geometry and generate optimized velocity profiles without user intervention. The automated calculation and application of optimal speeds maintains ease of operation while dramatically improving the speed-quality balance, eliminating the need for manual speed tuning.
Solution Approach 2:
The patent segments the print path into chord segments and applies different velocity optimizations to each segment. This segmentation approach maintains simplicity by automating the complex calculations while improving productivity through localized speed optimization, resolving the contradiction between ease of operation and performance.
Data Source
AI summary
A process for automatically adjusting print speed in a 3D printer, a system for printing a 3D object, and a method of printing a 3D object. A scaling factor is selected, including a first component for print speed and a second component for print quality, an extrusion nozzle port size is identified, and a maximum volumetric extrusion rate for a filament material and a minimum volumetric extrusion rate for the filament material is identified. An optimized volumetric extrusion rate is calculated from the maximum volumetric extrusion rate, the minimum volumetric extrusion rate, and the scaling factor. An optimized X-Y velocity Vxy of a print head based on the optimized volumetric extrusion rate is calculated. A computer numerical control code is adjusted to include the optimized X-Y velocity Vxy of the print head.