Hybrid Print Configuration Graphs for Low-Support 3D Manufacturing
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Solution Overview
Problem
Current additive manufacturing techniques require extensive use of support structures, which can be costly and time-consuming to remove, and may damage the target model, especially for complex shapes and large objects, increasing material and processing time costs.
Innovation Solution
The development of a system and method to generate Pareto-efficient hybrid manufacturing configurations that optimize support structures and printing orientations, allowing for automatic generation of multiple configurations considering factors like cost, time, and print failure likelihood, enabling users to select the most suitable configuration without explicitly defining all parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If support structures are used in additive manufacturing, then complex shapes and overhangs can be manufactured, but material cost and processing time increase
Solution Approach 1:
The system extracts and removes support structures from the final product after manufacturing is complete. The automated support removal system identifies and removes support material through processes like melting, dissolving, or mechanical removal, separating the support function from the final product to reduce material waste and processing time.
Solution Approach 2:
The system performs preliminary actions by pre-planning support structure placement and removal strategies before manufacturing begins. The software analyzes the 3D model to determine optimal support locations and removal methods in advance, enabling more efficient manufacturing and reducing post-processing time.
2Ease of manufacture
If support structures are used in additive manufacturing, then complex shapes and overhangs can be manufactured, but material cost increases
Solution Approach 1:
The system extracts and removes support structures from the final product after manufacturing is complete. The automated support removal system identifies and removes support material through processes like melting, dissolving, or mechanical removal, separating the support function from the final product to reduce material waste and processing time.
Solution Approach 2:
The system facilitates discarding support structures that serve their purpose during manufacturing but are not needed in the final product. By automating the removal process and optimizing support placement, the system minimizes material waste and enables recovery or disposal of support material more efficiently.
3Ease of manufacture
If support structures are used in additive manufacturing, then overhangs can be supported, but print quality may deteriorate due to damage to the target model
Solution Approach 1:
The system introduces an automated support removal mechanism as an intermediary between the support structures and the final product. This intermediary process carefully removes support material without damaging the target model, using controlled methods like selective melting, dissolving, or mechanical removal with precision control.
Solution Approach 2:
The system performs preliminary actions by pre-planning support structure placement and removal strategies before manufacturing begins. The software analyzes the 3D model to determine optimal support locations and removal methods in advance, enabling more efficient manufacturing and reducing post-processing time.
4Ease of manufacture
If support structures are used in additive manufacturing, then complex shapes can be manufactured, but device complexity increases due to support material management
Solution Approach 1:
The system creates a universal support removal mechanism that can handle multiple types of support structures and materials through a single automated process. The software platform provides multi-functional capabilities for analyzing, planning, and executing support removal strategies across different manufacturing scenarios, reducing the need for separate specialized processes.
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 material and processing time costs by minimizing support structures, improving print quality, and allowing users to make informed decisions based on Pareto-efficient solutions, thereby optimizing the 3D printing process.
Implementation Method 1
The support materials can be removed upon completion, such as by melting or dissolving.
Implementation Method 2
The support materials can be removed upon completion, such as by melting or dissolving.
Implementation Method 3
a layer of photo-sensitive polymer is jetted (similar to ink-jet printing) on a flat surface formed by the previous layer and cured into solid by ultra-violet (UV) light
Implementation Method 4
a molten string of filament is extruded and deposited by a hot-end nozzle into a sliced pattern in each layer, the molten string solidifies after exiting the hot-end nozzle
Data Source
AI summary
The present disclosure provides techniques for determining a configuration for 3D printing a 3D object. An example method includes obtaining user input parameters describing one or more user objectives. The method also includes computing, by a processing device, a graph of hybrid manufacturing (HM) configurations based in part on the user input parameters, wherein the graph comprises a plurality of nodes corresponding to different configurations for manufacturing the 3D object, wherein each node corresponds with a favorable print configuration with respect to two or more figures of merit. The method also includes displaying a selected HM configuration corresponding to a selected node of the plurality of nodes.