3D Printing Agent Density Control for Sloped Surface Quality
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Solution Overview
Problem
Layer-based 3D printing technologies face quality defects such as stair stepping on sloped surfaces due to quantization during the slicing process, and reducing layer thickness to mitigate this can lead to increased computation costs and additional defects like crazing.
Innovation Solution
A method that modifies print data to increase the density of printing agents on sloped portions of build material layers, causing a bleeding effect that solidifies previously unsolidified areas, thereby reducing stair stepping without altering object orientation or slice thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If layer thickness is reduced to mitigate stair stepping, then surface quality is improved, but computation costs increase and additional defects like crazing occur
Solution Approach 1:
The patent applies different printing agent densities to different regions of the build plate. Specifically, sloped portions receive a first density of printing agents while non-sloped portions receive a second density, where the first density is greater than the second. This local differentiation allows targeted improvement of surface quality on sloped surfaces without uniformly reducing layer thickness across the entire build, thereby avoiding the associated computation costs and crazing defects.
2Manufacturing precision
If layer thickness is reduced to mitigate stair stepping, then surface quality is improved, but new defects like crazing are introduced
Solution Approach 1:
The patent applies different printing agent densities to different regions of the build plate. Specifically, sloped portions receive a first density of printing agents while non-sloped portions receive a second density, where the first density is greater than the second. This local differentiation allows targeted improvement of surface quality on sloped surfaces without uniformly reducing layer thickness across the entire build, thereby avoiding the associated computation costs and crazing defects.
3Manufacturing precision
If printing agent density is increased on sloped portions, then stair stepping is reduced, but material consumption increases
Solution Approach 1:
The patent applies different printing agent densities to different regions of the build plate. Specifically, sloped portions receive a first density of printing agents while non-sloped portions receive a second density, where the first density is greater than the second. This local differentiation concentrates the additional printing agent usage only where needed (on sloped surfaces) rather than across the entire build plate, thereby reducing overall material consumption compared to a uniform approach.
Solution Approach 2:
The patent applies excessive printing agent density specifically to sloped portions where stair stepping occurs, rather than uniformly across the entire build plate. This partial application of excessive action targets the problem area precisely, achieving the needed surface quality improvement while minimizing overall material consumption.
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 effectively reduces stair stepping in 3D printed objects by selectively increasing agent density and causing thermal or wetting bleed, solidifying previously unsolidified volumes without modifying the printing process's resolution or slice thickness, thus improving surface quality.
Implementation Method 1
causing a bleeding effect that solidifies previously unsolidified areas
Implementation Method 2
causing a bleeding effect that solidifies previously unsolidified areas
Data Source
AI summary
A 3D printer is disclosed herein. The 3D printer comprises a build material distributor, an agent delivery device and a controller. The controller obtains slice image data of a sliced virtual build volume including a 3D object to be generated, where the slice image data is indicative, for each slice, of the portions of corresponding build material layers to be solidified. The controller is to determine print data corresponding to each slice, the print data defining a density of printing agent to be applied to regions of each layer based on the slice image data; and to obtain additional data relating to a portion of a slice that corresponds to a sloped portion of the 3D object. The controller is further to modify the determined print data to modify the density of printing agent to be printed at a portion of a given build material layer based on the additional data. The controller is also to control the build material distributor to generate a build material layer; and the agent delivery device to selectively eject the printing agent based on the modified print data.