Real-Time Adjustment for 3D Printed Architectural Structures
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Solution Overview
Problem
Current three-dimensional printing systems for architectural structures face inefficiencies in making real-time adjustments during the printing process, requiring recompilation of model files and manual overrides, which are time-consuming and can lead to inconsistencies in printed layers.
Innovation Solution
The system allows for real-time or near real-time adjustments to printer-readable instructions without recompiling the model file, applying changes directly to current and subsequent instructions, including adjustments to toolpath parameters and manual movements, ensuring printing consistency across layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If model file recompilation and re-slicing is performed to make design changes during printing, then design adaptability is improved, but printing time and productivity deteriorate
Solution Approach 1:
The patent segments the printing instruction set into individual layer instructions that can be independently modified. Instead of recompiling the entire model file, the system identifies and adjusts only the specific layer instructions that need modification, allowing design changes without affecting the overall printing process timeline
Solution Approach 2:
The system performs preliminary preparation by pre-processing the model file into layer instructions before printing begins. This allows real-time adjustments to be made by modifying existing layer instructions rather than requiring model recompilation during printing, thus maintaining productivity while enabling design adaptability
2Adaptability or versatility
If manual override is used to adjust printer head movement, then design adaptability is improved, but manufacturing precision deteriorates
Solution Approach 1:
The system implements feedback by automatically detecting manual printer head movements and using this information to adjust subsequent layer instructions. This closed-loop approach ensures that manual adjustments are captured and consistently applied, maintaining manufacturing precision while preserving design adaptability
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated control system that detects printer head position and automatically modifies layer instructions. This substitution eliminates human error and inconsistency in manual overrides while maintaining the ability to make design changes
3Productivity
If real-time adjustment to printer instructions is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The control system performs self-service by automatically detecting manual adjustments and generating the necessary layer instruction modifications without requiring external intervention. This self-contained approach improves productivity while managing complexity through automation rather than human-operated complexity
4Manufacturing precision
If model file modification is performed for small adjustments, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The system segments the design modification process by allowing direct editing of specific layer instructions rather than modifying the entire model file. This enables small structural adjustments to be made precisely where needed without the time penalty of full model recompilation and re-slicing
Solution Approach 2:
The patent applies partial action by modifying only the necessary portion of the printing instructions (specific layer instructions) rather than performing the complete action of recompiling the entire model file. This achieves the required manufacturing precision for small adjustments while minimizing time loss
Data Source
AI summary
Methods, apparatuses, and systems to provide real-time adjustment for the three-dimensional printing of architectural structures are disclosed herein. An example apparatus includes a printing control processor configured to receive a model file that specifies a three-dimensional representation of a building structure to be printed. The processor slices the model file into individual layers. Each layer has a height corresponding to a height of a layer to be printed. The processor converts the layers into computerized instructions for a three-dimensional printer. During printing, the processor receives adjustment information that is indicative of an adjustment made by the three-dimensional printer during the printing of a current layer. The processor applies the adjustment information to subsequent computerized instructions that are to be executed after printing the current layer. The processor then executes the computerized instructions for the subsequent layers including causing the three-dimensional printer to print the layers with the adjustment.