Non-Planar 3D Printing of Overhangs Without Support Structures
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Solution Overview
Problem
Conventional 3D printing systems require additional support structures for overhangs at angles greater than a certain threshold, increasing resin usage and leaving surface marks that can be difficult to remove.
Innovation Solution
A method and system for non-planar slicing and printing that tilts the build platform to reduce the angle of overhang structures below the threshold, eliminating the need for support structures by performing non-planar slicing based on the inclination angle of overhangs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If support structures are added to overhang structures with inclination angles greater than the threshold, then the overhang structure can be successfully printed without drooping or deformation, but the amount of resin used increases and surface marks are left on the object
Solution Approach 1:
The build platform is made dynamically tiltable to change its orientation during the printing process. By tilting the build platform, the effective inclination angle of overhang structures is reduced below the threshold angle, allowing them to be printed without support structures. This dynamic adjustment of the build platform angle enables successful printing of overhangs while minimizing resin usage and avoiding surface marks.
Solution Approach 2:
The system changes the geometric parameter of the build platform orientation by tilting it to a specific angle. This parameter change transforms the printing conditions by reducing the effective inclination angle of overhang structures, allowing them to fall within the printable range without requiring support structures, thus reducing resin consumption and eliminating surface marks.
2Reliability
If support structures are added to overhang structures, then the overhang structure can be successfully printed, but surface marks are left that require polishing to remove
Solution Approach 1:
The build platform is dynamically tilted to an optimal angle during printing, which reduces the effective inclination of overhang structures below the threshold. This allows the overhangs to be printed successfully without support structures, thereby eliminating the need for post-processing removal of support structures and associated surface marks.
Solution Approach 2:
By changing the build platform orientation parameter through tilting, the system enables successful printing of overhang structures without support structures. This parameter adjustment eliminates the need for subsequent polishing or removal operations, simplifying the manufacturing process.
3Loss of substance
If the build platform is tilted to reduce the angle of inclination of overhang structures, then support structures are eliminated and resin usage is reduced, but the slicing process becomes more complex requiring non-planar slicing
Solution Approach 1:
The system implements dynamic non-planar slicing that adapts to the tilted build platform orientation. The slicing process is adjusted to account for the tilted coordinate system, enabling accurate layer generation that follows the tilted platform surface. This complex slicing approach enables the build platform to be tilted for printing overhangs without support structures, thereby reducing resin usage.
Solution Approach 2:
The slicing process transitions from standard planar slicing to non-planar slicing that operates in a tilted coordinate system. This dimensional transformation allows the generation of toolpaths and layer definitions that correspond to the tilted build platform orientation, enabling successful printing at reduced resin consumption despite the increased computational complexity.
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 reduces resin usage and eliminates the need for post-processing removal of support structures, minimizing surface marks and enhancing the printing process efficiency.
Implementation Method 1
tilting the build platform to the build platform tilt angle
Data Source
AI summary
A system and method of non-planar slicing and three-dimensional (3D) printing of objects with at least one overhang structure. The system includes slicing software that performs non-planar slicing of the object's corresponding digital file, and control software that tilts the 3D printer's build platform during the printing of the overhang structure in accordance with the non-planar slicing information.