Rotary 3D Printer Scan Paths Using Helical Frame Slicing
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Solution Overview
Problem
Traditional additive manufacturing processes struggle to efficiently create industrial asset items using rotary machines, as slicing parts into horizontal layers is not feasible due to the continuous rotation and downward spiral motion, leading to scanner idle time and inefficient space utilization.
Innovation Solution
A system that approximates a helical slice with a series of two-dimensional, locally linear frames arranged as a spiral staircase, allowing for continuous building without layer-specific powder dispense and recoat, and utilizing multiple lasers to increase throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional horizontal layer slicing is used for rotary additive manufacturing, then the manufacturing process can be simplified, but scanner idle time increases and throughput decreases
Solution Approach 1:
The patent divides the continuous helical slicing problem into discrete two-dimensional frames that are arranged in a spiral staircase pattern. Each frame is processed independently by the scanner, allowing for efficient path planning and eliminating idle time between layers while maintaining manufacturing simplicity through standardized frame processing.
Solution Approach 2:
The patent transitions from traditional horizontal layer slicing (two-dimensional layers stacked vertically) to helical slicing where frames are arranged in a three-dimensional spiral staircase pattern. This dimensional transformation allows continuous scanning along the helical path, eliminating scanner idle time and improving throughput while maintaining process simplicity through algorithmic generation of frame sequences.
2Device complexity
If horizontal layer slicing is used in rotary additive manufacturing, then equipment complexity remains low, but space utilization for certain part geometries deteriorates
Solution Approach 1:
The patent employs helical slicing that arranges two-dimensional frames in a three-dimensional spiral staircase pattern, allowing better accommodation of complex part geometries such as tubes and curved structures. This dimensional approach improves space utilization without requiring additional equipment, as the same rotary additive manufacturing system can generate optimized frame sequences for any geometry.
3Productivity
If continuous rotation and downward spiral motion are implemented, then scanner idle time is reduced, but traditional horizontal layer slicing becomes infeasible
Solution Approach 1:
The patent inverts the traditional slicing approach by instead of slicing horizontal layers and then moving the build platform, it generates two-dimensional frames that are inherently arranged in a helical pattern. The scanner follows this helical path during continuous rotation, making the slicing feasible with rotary motion while maintaining high scanner utilization and eliminating idle time.
Solution Approach 2:
The patent implements dynamic frame generation where the two-dimensional frames are created based on the continuous rotary motion and downward spiral trajectory. The frame sequence adapts to the dynamic motion parameters, allowing the system to maintain feasibility of slicing while achieving continuous scanning and high scanner utilization throughout the manufacturing process.
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 enhances throughput by minimizing scanner idle time and improving space utilization for certain part geometries, while leveraging existing linear slicing algorithms to facilitate efficient creation of industrial asset items on rotary additive manufacturing machines.
Implementation Method 1
moving a laser beam in a pre-designed two-dimensional trajectory
Implementation Method 2
additive manufacturing process may create parts
Implementation Method 3
a build plate may rotate about a vertical axis and move, relative to a print arm, along the vertical axis during printing
Implementation Method 4
When the build platform of a rotary machine continuously rotates and drops down simultaneously (a downward spiral motion)
Data Source
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AI summary
Some embodiments facilitate creation of an industrial asset item via a rotary additive manufacturing process. For example, a build plate may rotate about a vertical axis and move, relative to a print arm, along the vertical axis during printing. An industrial asset item definition data store may contain at least one electronic record defining the industrial asset item. A frame creation computer processor may slice the data defining the industrial asset item to create a series of two-dimensional, locally linear frames helically arranged as a spiral staircase of steps (and each step may be oriented normal to the vertical axis. Indications of the series of two-dimensional frames may then be output to be provided to a rotary three-dimensional printer.