Laminated Shape Bead Mapping for Automatic Deposition Paths
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Solution Overview
Problem
Existing methods for additive manufacturing do not efficiently determine the depositing procedure for forming beads, relying heavily on worker experience and intuition, which can lead to inefficiencies and require skilled labor.
Innovation Solution
A method that produces a bead map from three-dimensional model data, allowing for the automatic determination of the depositing procedure by associating index numbers and flags with polygon faces, enabling continuous bead formation along specific directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automatic determination of depositing procedure is implemented, then productivity and efficiency are improved, but device complexity increases due to the need for sophisticated software algorithms and processing systems
Solution Approach 1:
The three-dimensional model data is divided into multiple polygon faces, which are then organized into columns along a predetermined direction. This segmentation allows the complex depositing procedure to be broken down into manageable units that can be processed systematically, enabling automatic determination without overwhelming system complexity.
Solution Approach 2:
The invention introduces a bead map that associates index numbers and flags with polygon faces, adding a dimensional layer of organization to the three-dimensional model data. This dimensional transformation enables efficient automatic processing by creating a structured representation that simplifies the determination of depositing procedures.
2Manufacturing precision
If bead formation is continuously formed along specific directions, then manufacturing precision is improved, but the complexity of determining the depositing procedure increases
Solution Approach 1:
The invention applies different flags (bead formation ON flag and OFF flag) to different polygon faces based on their specific characteristics and positions. This local differentiation allows precise control of bead formation at each location while maintaining overall system manageability through standardized flag processing.
Solution Approach 2:
The bead map is generated in advance, pre-associating index numbers and flags with all polygon faces before the actual depositing process begins. This preliminary organization of data simplifies the real-time processing during manufacturing, as the depositing procedure can be executed by simply following the pre-determined bead map without complex real-time calculations.
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 allows for efficient and automatic determination of the depositing procedure, improving the efficiency of additive manufacturing by reducing reliance on worker skill and experience.
Implementation Method 1
A 3D printer for depositing a metal material produces an additively-manufactured object by melting a metal powder or a metal wire by use of a heat source such as a laser, an electron beam, and an arc
Implementation Method 2
vaporizing the filler metal Fm, and depositing the vaporized filler metal Fm
Implementation Method 3
In the case of using an arc, a filler metal is melted by the arc
Implementation Method 4
a filler metal is melted by the arc, and then solidified to form a bead
Data Source
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AI summary
According to the present invention, the shape of a laminated shaped product is divided into a plurality of polygon planes, and index numbers are added to the polygon planes. A flag indicating that bead formation is ON is added to each polygon plane excluding a terminal end polygon plane, and a flag indicating that bead formation is OFF is added to the terminal end polygon plane. Bead formation is executed at the position of each polygon plane for which bead formation is ON. A bead continuous formation path is acquired by stopping the bead formation at a position where the polygon plane with the flag indicating that bead formation is OFF is reached from the polygon planes with the flags indicating that bead formation is ON. Beads are continuously formed along the bead continuous formation path, thereby shaping the laminated shaped product.