Non-Planar Toolpaths for Material Extrusion
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Solution Overview
Problem
Existing material extrusion techniques struggle to form components with non-planar outer surfaces efficiently, often relying on multiple planar layers with steps and thick layers to achieve non-planarity, which can be cumbersome and limit design flexibility.
Innovation Solution
The method involves forming a component using first and second filaments that extend along multiple axes in a three-dimensional space, with the option of using primary and infill materials like chopped fibers or beads, and controlling their deposition to create a monolithic structure with non-planar features such as perforations and curved surfaces, allowing for enhanced design complexity and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If multiple planar layers with distinct widths are used to form non-planar surfaces, then non-planar outer surfaces can be achieved, but the process becomes cumbersome and design flexibility is limited
Solution Approach 1:
The patent transitions from depositing material in a single planar direction to depositing material along multiple axes in three-dimensional space. The nozzle moves along first, second, and third axes that are non-coplanar, enabling direct formation of non-planar surfaces without requiring multiple planar layers with varying widths. This dimensional approach eliminates the need for step-covering thick layers and simplifies the overall manufacturing process.
2Adaptability or versatility
If material is deposited in a planar manner layer by layer, then the component structure is formed, but the ability to create complex non-planar geometries is restricted
Solution Approach 1:
The patent employs dynamic nozzle movement along multiple non-coplanar axes rather than static planar layer deposition. The nozzle can change its deposition direction and orientation continuously in three-dimensional space, allowing adaptation to complex non-planar geometries. This dynamic approach enables the system to accommodate varying design requirements while maintaining manufacturing efficiency through automated control.
3Strength
If crossing filaments along multiple axes are deposited, then strength along multiple axes and precise perforation control are achieved, but the device complexity increases
Solution Approach 1:
The patent uses a single nozzle system that performs multiple functions: depositing material along first axes to form primary filaments, then moving along second and third axes to form crossing filaments. The same nozzle that deposits material can also create perforations by controlling the deposition pattern. This multi-functional approach achieves enhanced strength along multiple axes and precise perforation control without requiring separate systems for each function.
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 enables the creation of components with precise control over perforation size and shape, improved strength along multiple axes, and reduced drag, making it suitable for applications like acoustic treatments in gas turbine engines where noise reduction and durability are critical.
Implementation Method 1
In a material extrusion process, layers of a material are placed down upon each other to form the component structure
Implementation Method 2
the forming steps including depositing material in a heated environment
Data Source
AI summary
A method of forming a component by material extrusion includes the steps of forming a plurality of first filaments extending along at least a first axis of a three dimensional space and forming a plurality of second filaments crossing the plurality of first filaments by extending in a direction with at least a component along second and third axes in the three dimensional space.