Additive Nozzle Tool Paths from Reversed Cutting Paths

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Solution Overview

Problem

In additive manufacturing, determining an appropriate tool path for a three-dimensionally movable nozzle is challenging, especially when considering motion in a plane for solidification, leading to inefficiencies in creating desired shapes and requiring trial and error for parameter optimization.

Innovation Solution

A method is developed to generate control data for additive manufacturing by determining a cutting path and reversing it to create the nozzle path, allowing for precise control of the nozzle's motion, powder supply, and laser output, optimizing parameters such as speed, powder amount, and laser intensity to achieve the desired product shape.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a method for stacking thin films layer by one by one (powder bed method) is used, then the process is simple and controllable, but the shape creation freedom is limited

Engineering Contradiction:

Improveprocess simplicityVSAvoidshape creation freedom

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent applies inversion by reversing the conventional additive manufacturing logic. Instead of building up layer by layer (additive approach), the system uses subtractive manufacturing logic where a cutting path is determined first and then reversed to generate the additive tool path. This allows the system to leverage well-established subtractive manufacturing algorithms while achieving additive manufacturing goals, thus maintaining process simplicity while greatly enhancing shape creation freedom

Inventive Principle:

Principle #13The other way round (Inversion)

2Adaptability or versatility

If a three-dimensionally movable nozzle is used for cladding, then shape creation freedom is improved, but determining the appropriate tool path becomes more difficult

Engineering Contradiction:

Improveshape creation freedomVSAvoidtool path determination complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent resolves this complexity by inverting the problem-solving approach. Rather than directly determining the complex three-dimensional tool path for the movable nozzle, the system first determines a cutting path (as if performing subtractive machining) and then reverses this path to generate the additive tool path. This inversion transforms a complex three-dimensional path planning problem into a more manageable process that leverages conventional CNC machining algorithms

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent introduces an intermediary step in the tool path generation process. The cutting path serves as an intermediary representation that bridges the gap between the desired final shape and the actual additive manufacturing tool path. By using this intermediate cutting path (which can be easily determined using conventional CAM software) and then reversing it, the system avoids the complexity of directly calculating the three-dimensional additive tool path

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If trial and error is used for parameter optimization, then the system is flexible, but time consumption increases

Engineering Contradiction:

Improveparameter optimization flexibilityVSAvoidoptimization time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-determining the tool path using the reverse cutting path method before actual manufacturing begins. By calculating the optimal path in advance through the inversion process (reversing the cutting path), the system eliminates the need for time-consuming trial and error adjustments during manufacturing. The control data is generated with optimized parameters from the start, significantly reducing total process time while maintaining the flexibility to handle different shapes

Inventive Principle:

Principle #10Preliminary action

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 eliminates the need for trial and error, ensuring accurate and efficient creation of desired shapes with improved surface roughness and dimensional accuracy, while optimizing heat transfer and material deposition for enhanced product quality.

Implementation Method 1

a method for generating a tool path in a stacked layer creating step in a powder bed method

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

emitting laser while applying powders from a nozzle

Methodology Applied

Scientific EffectMelting and solidification: Melting

Data Source

PatentUS10889098B2Method, data processing device, and machine tool for generating dimensional tool paths and control signals for material dispositioning

Publication Date: 2021.01.12 MACHINE TOOL TECH RES FOUND

AI summary

A method for generating control data is a method for generating control data for manufacturing a product having a designated shape using an additive manufacturing technology. The control data includes a path of a nozzle for supplying a material. The method for generating the control data includes: determining a cutting path for cutting the designated shape by a tool; and determining the path of the nozzle by reproducing the cutting path temporally reversely.