GRAPE Data Format for Compact Complex-Shape 3D Printing
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Solution Overview
Problem
Existing 3D printing technologies face inefficiencies with complex data formats like STL, leading to large data sizes and slower processing times, especially when dealing with complex shapes and problematic materials, which affect accuracy and speed.
Innovation Solution
The implementation of the Graphical Rectangular Actual Positional Encoding (GRAPE) data format, which uses two-dimensional positional coordinates of rectangular forms to define 3D models, along with adaptable printing techniques for materials, including continuous spraying and droplet deposition, and the use of control software for precise material delivery configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If STL data format is used to describe 3D surface geometry, then the 3D model can be represented, but the data file size becomes very large for complex shapes
Solution Approach 1:
The patent segments the 3D model into a set of rectangular primitives (boxes) rather than using complex surface geometry. Each rectangle is defined by simple corner coordinates, breaking down the complex shape into manageable, easily representable units. This segmentation dramatically reduces data requirements while maintaining the ability to reconstruct the original 3D model.
Solution Approach 2:
The patent creates a simplified representation (copy) of the 3D model using rectangular primitives instead of exact surface geometry. This copy preserves the essential shape and structure information while using minimal data, allowing accurate reconstruction without storing the original complex surface details.
2Productivity
If STL data format is used for 3D printing, then the 3D model can be printed, but the processing time increases for complex shapes
Solution Approach 1:
By segmenting the 3D model into rectangular primitives with simple corner coordinates, the patent reduces the computational complexity of processing the model. The printer can quickly interpret and execute instructions for simple rectangular shapes rather than complex surface geometries, significantly reducing processing time while maintaining printing capability.
3Manufacturing precision
If standard 3D printing techniques are used, then materials can be deposited, but accuracy decreases for problematic materials
Solution Approach 1:
The patent implements dynamic control of the printing process, allowing the dispensing part to move relative to the bed or previously printed features. This dynamic positioning enables precise material deposition for problematic materials by adjusting the print head position based on material viscosity and deposition requirements, achieving both accuracy and material versatility.
4Productivity
If continuous spraying mode is used for low viscosity materials, then material deposition is efficient, but control precision decreases
Solution Approach 1:
The patent incorporates feedback mechanisms that monitor material deposition and adjust the dispensing process in real-time. For continuous spraying of low viscosity materials, the system uses feedback to maintain precise positioning and control, ensuring accuracy is preserved while benefiting from the high deposition speed of continuous spraying mode.
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 significantly reduces data file sizes by up to 40 times compared to STL, enhances printing accuracy, and allows for quicker and more precise 3D printing of complex models, particularly in bioprinting applications with diverse materials.
Implementation Method 1
a printing mode for continuous spraying of a low viscosity material while a dispensing part moves relative to a bed of a printing machine or a previously printed feature printed part
Implementation Method 2
a printing mode for extrusion of a droplet of a viscous, or semi-viscous, material whilst a dispensing part is substantially stationary at a first location
Data Source
AI summary
Disclosed is a method for preparing a data set for a construct to be printed in layers. the method comprising using a computer program to carry out the steps of: a) defining in a two-dimensional plane a layer of the construct in terms of one or more polygonal primitives: b) for each primitive defining a set of first and second coordinates in the two dimensions representing corner points of the or each primitive: c) defining a common third coordinate based on the thickness of the or each primitive perpendicular to the two-dimensional plane: and d) forming a data set based on the first second and third coordinates. The data set can be manipulated further to produce start and stop points for printing. The data set can describe a 3D printable object with significantly less data than a conventional STL data file. The invention extends to improved modes of dispensing print material including droplet dispensing while a printhead is stationary. and 3D printing apparatus for said improved dispensing.