3D Printed Outer Wall Segmentation for Smoothness and Time
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Solution Overview
Problem
In extrusion-based additive manufacturing, achieving enhanced smoothness of the outer surface of 3D printed objects increases printing time, leading to higher costs and reduced throughput.
Innovation Solution
The method involves dividing the outer wall into a high-resolution first outer wall part and a low-resolution second outer wall part, with the first part forming the enhanced smooth surface using a stack of sublayers and the second part filled with main layers, optimizing track width and height to minimize printing time while maintaining smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the thickness of tracks of feedstock material is reduced to improve smoothness of the outer surface, then the smoothness of the outer surface is improved, but the printing time increases
Solution Approach 1:
The outer wall is divided into two distinct parts: a first outer wall part with enhanced smoothness and a second outer wall part with standard smoothness. This segmentation allows different regions to be printed with different track thicknesses, applying the principle of local quality optimization.
Solution Approach 2:
Different regions of the outer wall are assigned different quality levels. The first outer wall part uses thin tracks (0.05-0.2mm) for enhanced smoothness in visible areas, while the second outer wall part uses standard tracks (0.1-0.5mm) for less critical areas, optimizing both smoothness and printing time locally.
2Manufacturing precision
If the thickness of tracks of feedstock material is reduced to improve smoothness of the outer surface, then the smoothness of the outer surface is improved, but the throughput of the 3D printing system decreases
Solution Approach 1:
The outer wall is segmented into high-quality and standard-quality regions, allowing the system to maintain high throughput by printing standard tracks in less critical areas while only using time-consuming thin tracks where enhanced smoothness is visually important.
Solution Approach 2:
The invention applies local quality optimization by reserving thin track printing for specific regions where it provides visible aesthetic benefit, while using standard track thickness elsewhere to preserve overall printing speed and throughput.
3Manufacturing precision
If the thickness of tracks of feedstock material is reduced to improve smoothness of the outer surface, then the smoothness of the outer surface is improved, but the costs of the 3D printed objects increase
Solution Approach 1:
By segmenting the outer wall into two parts with different track thickness requirements, the invention reduces the total printing time compared to printing the entire outer wall with thin tracks, thereby reducing costs while maintaining enhanced smoothness where needed.
Solution Approach 2:
The invention optimizes costs by applying expensive thin track printing only to regions where enhanced smoothness is visually important, while using cheaper standard track printing for less critical areas, achieving cost-effective quality improvement.
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 additional printing time for the outer surface with enhanced smoothness, thereby decreasing overall printing time and costs without compromising the smoothness of the 3D printed object.
Implementation Method 1
a printhead that is moveable in a 3D space with respect to a build plate while dispensing feedstock material on at least one of the build plate and on previously deposited tracks of the feedstock material
Implementation Method 2
The feedstock material can be thermally or chemically or otherwise fused with the previously deposited tracks
Implementation Method 3
The feedstock material can be thermally or chemically or otherwise fused with the previously deposited tracks
Implementation Method 4
The feedstock material is dispensed from the printhead through a feedstock liquefying unit and is deposited on the build plate in the form of tracks
Data Source
AI summary
A method for reducing an additional printing time of a 3D object related to printing of an outer wall of the 3D object, the outer wall having an outer surface with an enhanced smoothness. The outer wall is arranged to envelope an inner part of the 3D object. The outer wall includes at least one region having a first outer wall part and a second outer wall part. The first outer wall part forms the outer surface with the enhanced smoothness. The second outer wall part is arranged between the first outer wall part and the inner part and provides a low-resolution part of the outer wall having a less smooth outer surface than the first outer wall part. Hence, the additional printing time related to printing the outer wall having an outer surface with an enhanced smoothness can be reduced. A 3D printing system adapted to perform the method and to a 3D printed object having the abovementioned outer wall.