Non-Planar Layer Extrusion for Stress-Aligned Additive Manufacturing
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Solution Overview
Problem
Extrusion-based additive manufacturing systems face limitations in creating objects with improved structural properties, particularly in managing stress distribution and maintaining stable flow dynamics during the deposition of non-planar layers.
Innovation Solution
The method involves extruding material from an extrusion head with controlled relative movement between the extrusion head and the tool, including rotation, to shape layers according to a three-dimensional model, allowing for non-planar layers that follow stress lines and maintaining a constant tilt angle for stable flow, using either thermoplastic, thermosetting, or photocurable materials with heterogeneous structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If planar layers are deposited using conventional extrusion methods, then the manufacturing process is simple and stable, but the structural properties and stress distribution of the object are limited
Solution Approach 1:
The system transitions from static planar layer deposition to dynamic non-planar layer deposition with continuous orientation changes. The extrusion head rotates and tilts during deposition to create layers that follow stress lines, transforming the manufacturing process from rigid and simple to flexible and adaptive, thereby improving structural properties while managing complexity through controlled motion.
Solution Approach 2:
The invention adds rotational and tilting dimensions to the conventional linear extrusion process. By introducing rotation about the build axis and tilting of the extrusion head, the system creates non-planar layers in three-dimensional space that conform to stress distribution patterns, enhancing structural properties through multi-dimensional layer geometry.
2Shape
If the orientation between extrusion axis and tool changes during deposition to follow non-planar layer shape, then layers can be shaped according to stress patterns, but stable flow dynamics from extrusion head to layer cannot be maintained
Solution Approach 1:
The system pre-calculates and pre-plans the extrusion head orientation and tilt angle throughout the deposition process. By determining the complete motion path and orientation sequence before deposition begins, the system ensures that the tilt angle remains constant even as the head rotates and follows non-planar layer geometries, thereby maintaining stable flow dynamics while achieving complex layer shapes.
Solution Approach 2:
The system continuously monitors and adjusts the extrusion head orientation and tilt angle during deposition to maintain the constant tilt angle condition. Through real-time feedback control, the system ensures that as the extrusion head rotates to follow non-planar layer shapes, the tilt angle relative to the layer surface remains constant, preserving stable flow dynamics throughout the process.
3Stability of the object's composition
If constant tilt angle is maintained during non-planar layer deposition, then stable flow dynamics are achieved, but the ability to follow complex stress line patterns is limited
Solution Approach 1:
The system employs dynamic motion control where the extrusion head simultaneously performs rotation about the build axis and maintains a constant tilt angle. This dynamic coordination allows the deposition path to follow complex non-planar stress line patterns while the constant tilt angle ensures stable material flow from the extrusion head, resolving the contradiction between geometric conformity and flow stability.
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 enhances the structural properties of the manufactured objects by aligning layers with stress patterns and maintaining stable flow dynamics, resulting in improved resistance to stresses like hoop stress, and allows for the use of different materials and tools with varying properties.
Implementation Method 1
The material may be a thermoplastic material which cures by cooling
Implementation Method 2
a thermosetting material which is cured by heating
Implementation Method 3
a material which is cured by some other mechanism (such as by photocuring or reacting with a chemical curing agent)
Implementation Method 4
The tool may be dissolved by the action of a liquid dissolving agent
Data Source
AI summary
A method of manufacturing an object is disclosed. Material is extruded from an extrusion head onto a tool, the extrusion head having an extrusion axis along which the material flows as it exits the extrusion head. Relative movement is generated between the extrusion head and the tool as the material is extruded so that the material is deposited as a series of layers, wherein the material cures on or after deposition so that the layers are fused together. The extrusion and the relative movement are controlled so that the series of layers are shaped in accordance with a stored three-dimensional model of the object. At least some of the layers are non-planar layers.