Multi-Stage Filaments for Smooth 3D Printing Surfaces

Solution Overview

Problem

Current fused-deposition modeling techniques in 3D printing often result in stepped surfaces due to the size of filaments, limiting the accuracy and aesthetics of created objects.

Innovation Solution

The use of multi-stage filaments and advanced control systems that apply filaments at precise angles and thicknesses to create smoother surfaces, with support structures that reduce droop and eliminate steps, enabling the production of complex designs with smooth finishes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If standard fused deposition modeling is used, then 3D objects can be created with complex designs, but the surface becomes stepped and rough due to filament size

Engineering Contradiction:

Improvedesign complexityVSAvoidsurface smoothness

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The printing process is divided into multiple stages: first printing the base object with standard filaments, then printing additional filaments at different angles and positions to fill gaps and smooth surfaces. This segmentation allows the system to maintain design complexity while improving surface smoothness through sequential refinement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces angular dimension to the printing process by printing filaments at multiple angles (e.g., 0 degrees, 45 degrees, 90 degrees) relative to the surface. This multi-angular approach fills the voids between standard horizontal filaments, creating a smoother surface without compromising design complexity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If larger filaments are used for printing, then printing speed increases, but surface accuracy and smoothness deteriorate

Engineering Contradiction:

Improveprinting speedVSAvoidsurface accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The printing process is divided into multiple stages: first printing the base object with standard filaments, then printing additional filaments at different angles and positions to fill gaps and smooth surfaces. This segmentation allows the system to maintain design complexity while improving surface smoothness through sequential refinement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces angular dimension to the printing process by printing filaments at multiple angles (e.g., 0 degrees, 45 degrees, 90 degrees) relative to the surface. This multi-angular approach fills the voids between standard horizontal filaments, creating a smoother surface without compromising design complexity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Manufacturing precision

If multi-stage filaments are applied to smooth surfaces, then surface smoothness improves, but device complexity increases

Engineering Contradiction:

Improvesurface smoothnessVSAvoidprinting process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The same 3D printing device performs multiple functions: it first prints the base object structure, then prints smoothing filaments at different angles. This multi-functionality is achieved through automated control that sequences the printing operations, reducing the need for additional specialized equipment while improving surface smoothness.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system uses its own printing capability to smooth surfaces by depositing additional filaments, rather than requiring separate smoothing equipment. The control system automatically determines which areas need smoothing and applies filaments accordingly, making the device self-sufficient for both structure creation and surface refinement.

Inventive Principle:

Principle #25Self-service

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 the creation of smoother surfaces and more accurate 3D objects by reducing the size of steps between layers, enhancing both the precision and aesthetics of printed items.

Implementation Method 1

Current techniques for three-dimensional (3D) printing include photopolymerization, granular-materials binding, and fused deposition modeling. In the case of fused deposition modeling, layers of material, such as sugar, plastic, or metal, are extruded

Methodology Applied

Scientific EffectFused deposition modeling: Extrusion

Implementation Method 2

with support structures that reduce droop and eliminate steps

Methodology Applied

Scientific EffectDroop reduction:

Data Source

PatentUS9908291B2Smooth 3D printing using multi-stage filaments

Publication Date: 2018.03.06 ADOBE INC

AI summary

This document describes techniques and apparatuses for smooth 3D printing using multi-stage filaments. These techniques are capable of creating smoother surfaces than many current techniques. In some cases, the techniques determine a portion of a surface of a 3D object that includes, or will include, a printing artifact or is otherwise not smooth, and then applies multi-stage filaments to provide a smoothing surface over that portion.