Level Set Shape Modification for Additive Manufacturing Support Reduction
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Solution Overview
Problem
Additive manufacturing techniques require support structures for overhangs, which are costly and time-consuming to produce and remove, and can damage the target model, especially for complex shapes where orientation changes do not adequately reduce support structure needs.
Innovation Solution
The use of level set representation and computational methods to modify shape features automatically, reducing or eliminating the need for support structures by morphing overhangs into new shapes that require less or no support, while preserving the original shape fidelity and allowing for subsequent removal by subtractive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If support structures are added to enable additive manufacturing of overhangs, then manufacturing capability is improved, but material cost and production time increase
Solution Approach 1:
The patent extracts and removes support structures from the final product by implementing a two-material printing process where support material is distinctly separated from the primary material, enabling automated support removal and reducing material waste in the final product
Solution Approach 2:
The patent changes material parameters by using two distinct materials with different properties (primary material and support material) where the support material is specifically selected to be removable through dissolution or melting, thereby reducing material cost and waste in the final product
2Ease of manufacture
If support structures are added to enable additive manufacturing of overhangs, then manufacturing capability is improved, but production time increases
Solution Approach 1:
The patent performs preliminary action by automatically generating support structures during the slicing and support generation phase before printing, and automatically removing them after printing through dissolution or melting, thereby reducing manual intervention time and accelerating the overall production process
Solution Approach 2:
The patent implements self-service by designing support structures that automatically dissolve or melt away after serving their support function during printing, eliminating the need for manual support removal and significantly reducing production time
3Ease of manufacture
If support structures are added to enable additive manufacturing of overhangs, then manufacturing capability is improved, but model damage risk increases
Solution Approach 1:
The patent extracts support structures as a separate removable component using two-material printing, where support material is specifically chosen to be dissolvable or meltable, thereby preventing damage to the primary model during support removal
Solution Approach 2:
The patent changes the material parameters of support structures to be chemically or thermally distinct from the primary material, enabling selective removal through dissolution or melting without affecting the integrity of the primary model
4Ease of manufacture
If support structures are added to enable additive manufacturing of overhangs, then manufacturing capability is improved, but process complexity increases
Solution Approach 1:
The patent implements universality by using the same additive manufacturing system to print both primary structures and support structures in a single integrated process, and using automated dissolution or melting to remove supports, thereby simplifying the overall process despite the added capability
Solution Approach 2:
The patent applies self-service by designing support structures that automatically dissolve or melt away after printing, eliminating the need for complex manual support removal processes and reducing overall process complexity
5Quantity of substance
If orientation is changed to reduce support structures, then support requirements are reduced, but new overhangs are introduced
Solution Approach 1:
The patent implements dynamics by allowing the system to automatically adjust support structure placement and orientation based on the specific geometry of each part, optimizing support requirements for complex shapes like flowers with radiating petals regardless of orientation
Solution Approach 2:
The patent changes the parameters of support structure generation by using automated algorithms that analyze part geometry and optimize support placement and orientation, thereby reducing support requirements for complex shapes without introducing excessive new overhangs
Data Source
AI summary
The present disclosure provides techniques for automatically modifying shape features related to overhangs such that support structures can be reduced or avoided. In an example, a shape modification processing device may obtain an initial shape and relevant production information (e.g., overhang angle threshold). The shape modification processing device may modify the shape to improve various aspects of production, including reduction or removal of the need for support materials or structures during additive manufacturing, with considerations that allow the modified portion (e.g., added features) be accessible for removal by subtractive manufacturing. For example, the shape modification processing device may modify a model to reduce or remove support structures needed during production. The added features may later be removed by subtractive manufacturing to restore any functional or desired shape.