3D Model Printing with Intrinsic Curved Paths for Stronger Parts
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Solution Overview
Problem
Traditional 3D printing methods that slice 3D objects into parallel planes often result in suboptimal surface finish and mechanical strength due to slicing orientation and print-path limitations, failing to fully utilize the intrinsic structure of the object.
Innovation Solution
Generating a set of non-planar univariate curves that cover the volume of the 3D object within a tolerance requirement, using these curves as printing paths to create improved surface finish and mechanical strength, and incorporating external directional vector fields for curve fitting and ordering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional slicing methods are used to divide 3D objects into parallel planes, then the printing process is simplified and can be easily implemented, but the surface finish and mechanical strength of the printed object deteriorate
Solution Approach 1:
The patent divides the 3D object volume into multiple layers using parallel slicing planes, but then further segments each layer into multiple non-planar univariate curves that follow the intrinsic geometry. This dual segmentation approach maintains the simplicity of layer-by-layer printing while improving surface finish by aligning print paths with the object's natural contours rather than forcing straight-line trajectories across each layer.
Solution Approach 2:
The patent employs non-planar univariate curves with varying curvature to define print paths within each slicing layer. These curved paths adapt to the local geometry of the 3D object, allowing the extrusion head to follow smooth contours that match the object's intrinsic structure. This curvature-based approach significantly improves surface finish quality compared to traditional straight-line or arc-based G-code paths.
2Ease of manufacture
If traditional slicing methods are used to divide 3D objects into parallel planes, then the printing process is simplified and can be easily implemented, but the mechanical strength of the printed object deteriorates
Solution Approach 1:
The patent segments each slicing layer into multiple univariate curves that are optimally distributed to provide structural reinforcement. By dividing the layer into multiple curved paths rather than printing as a single continuous path or using traditional raster patterns, the structure gains more load-bearing pathways that follow the object's intrinsic geometry, thereby improving mechanical strength while maintaining manufacturing simplicity.
Solution Approach 2:
The patent applies different print path densities and curvatures to different regions of each layer based on local geometric requirements. Areas with higher curvature or more complex geometry receive more densely packed or differently oriented univariate curves, providing localized structural reinforcement where needed. This local quality approach optimizes mechanical strength without requiring complete redesign of the entire printing process.
3Manufacturing precision
If non-planar univariate curves are used to cover the volume of the 3D object, then the surface finish and mechanical strength are improved, but the complexity of the printing path calculation increases
Solution Approach 1:
The patent segments the complex task of generating printing paths into two manageable stages: first, divide the 3D volume into parallel slicing layers; second, generate non-planar univariate curves within each layer. This segmentation reduces calculation complexity by breaking down the monolithic path-planning problem into smaller, more tractable sub-problems that can be solved independently for each layer, while still achieving high surface finish quality.
Solution Approach 2:
The patent uses mathematical models for non-planar univariate curves that, while geometrically complex, follow standardized parametric formulations. These curve definitions use controlled mathematical expressions that balance geometric fidelity with computational efficiency, allowing the system to generate high-precision curved paths without requiring excessively complex calculation algorithms.
4Strength
If non-planar univariate curves are used to cover the volume of the 3D object, then the mechanical strength is improved, but the computation time for generating printing paths increases
Solution Approach 1:
The patent segments the computation into independent layer-by-layer processing, where each layer's univariate curves are generated separately. This segmentation enables parallel computation of different layers and allows the system to terminate or pause between layers if needed, reducing overall computation time while maintaining the mechanical strength benefits of curved paths in each layer.
Solution Approach 2:
The patent generates univariate curves that provide sufficient coverage of each layer's volume, using a density that balances computational efficiency with structural reinforcement needs. Rather than generating excessively dense curves that would maximize strength but increase computation time, the system uses an optimized curve density that achieves adequate mechanical strength with reasonable computational effort.
Data Source
AI summary
There is provided a method of representing a three dimensional (3D) object using univariate curves, comprising: receiving an initial definition of a 3D object representation, calculate a covering set of univariate curves, the covering set comprising at least one non-planar univariate curve, wherein the covering set of univariate curves represent the volume of the 3D object within a tolerance requirement, and generating a representation of the 3D object based on the set of univariate curves, wherein the set of univariate curves represent the volume of the 3D object.