Flat-Bottom 3D Printing Layers With Local Deposition Rate Control
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Solution Overview
Problem
Additive manufacturing processes face challenges in maintaining build quality when depositing fluid agents on regions with flat bottom surfaces that are supported by non-solidified build material, leading to defects and reduced quality due to uncontrolled movement of the fluid agents.
Innovation Solution
The method involves identifying sets of base, bulk, and optionally transition layers in the build model, assigning distinct deposition rates based on layer characteristics, and adjusting the fluid agent deposition rate accordingly to minimize defects and enhance build quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fluid agents are deposited at a uniform rate across all layers, then the deposition process is simple and fast, but defects occur on flat bottom surfaces due to uncontrolled movement of fluid agents on non-solidified build material
Solution Approach 1:
The patent applies different deposition rates to different regions of the build plate. Specifically, regions identified as flat bottom surfaces (where defects occur) receive a reduced deposition rate, while other regions maintain the normal deposition rate. This localized adjustment improves build quality at critical areas without unnecessarily complicating the overall deposition process.
Solution Approach 2:
The build plate is segmented into different regions based on their characteristics - specifically identifying flat bottom surface regions versus other regions. This segmentation allows the system to apply different deposition strategies to different segments, resolving the contradiction by targeting complexity only where necessary to prevent defects.
2Manufacturing precision
If the deposition rate is reduced to prevent defects on flat bottom surfaces, then build quality improves, but the overall productivity of the additive manufacturing process decreases
Solution Approach 1:
Instead of reducing the deposition rate across the entire build plate, the patent applies the reduced rate only to specific regions identified as flat bottom surfaces. This localized approach maintains high productivity in non-critical areas while ensuring quality in defect-prone areas, thus resolving the productivity-precision contradiction.
Solution Approach 2:
The build plate is divided into regions requiring different deposition rates. By segmenting the build area and applying rate adjustments only where necessary (on flat bottom surfaces), the system preserves overall productivity while achieving improved build quality at critical locations.
3Productivity
If fluid agents are deposited on regions with flat bottom surfaces supported by non-solidified material, then the additive manufacturing process can proceed without interruptions, but defects and reduced quality occur due to uncontrolled movement of fluid agents
Solution Approach 1:
The system performs preliminary identification of flat bottom surface regions before deposition begins. By pre-mapping these problematic areas and preparing a customized deposition rate profile in advance, the system can proceed with continuous manufacturing while preventing defects through pre-planned local rate adjustments.
Solution Approach 2:
The patent applies quality control measures specifically to regions where defects are likely to occur (flat bottom surfaces), while maintaining normal deposition conditions elsewhere. This localized quality management allows continuous processing without compromising surface quality at critical areas.
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 reduces defects and enhances the overall build quality by optimizing the deposition rate for different layer types, thereby improving the efficiency and consistency of the additive manufacturing process.
Implementation Method 1
applying heat energy from an energy source in order to, for example, fuse, sinter, melt, or otherwise join the build material
Implementation Method 2
selectively depositing fluid agents onto portions of those layers, and applying energy to cause those portions of each layer onto which an energy absorbing fluid agent has been deposited to absorb the energy
Data Source
AI summary
A method comprising dividing a build model comprising an object model arranged within a virtual volume into cross-sectional layers along a vertical axis. The layers represent layers of an additive manufacturing process. A set of base layers is identified with each of the base layers comprising a flat bottom surface of the object model. A base characteristic is assigned to the set of base layers. A set of bulk layers is identified which excludes the set of base layers. A bulk characteristic is assigned to the set of bulk layers. An additive manufacturing apparatus is instructed to build a build cake according to the build model, layers and assigned characteristics, so a fluid agent is deposited at a first rate for the set of bulk layers having the bulk characteristic and a second rate, slower than the first rate, for the set of base layers having the base characteristic.