3D Model Seam Concealment via Interior Tool Path Adjustment
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Solution Overview
Problem
Extrusion-based digital manufacturing systems face challenges in creating aesthetically pleasing and functionally sound 3D models due to visible seams formed at the intersection of start and stop points during the layer-by-layer deposition process, which can result in bulges or porosity issues.
Innovation Solution
Adjusting the start and stop points of contour tool paths to locations within the interior region of a 3D model layer, allowing for concealed seams and improved seam sealing, thereby reducing porosity and enhancing the model's aesthetic and functional qualities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the extrusion head deposits modeling material following a contour tool path with start and stop points on the perimeter, then the layer can be efficiently formed, but visible seams and bulges appear at the intersection points
Solution Approach 1:
The patent applies preliminary action by positioning the start and stop points of the contour tool path within the interior region before the extrusion process begins. This pre-positioning ensures that the seams will be formed inside the model rather than on the visible perimeter, preventing seam visibility issues before they occur. The host computer generates modified tool path data that anticipates and prevents the seam problem rather than correcting it after formation.
2Ease of manufacture
If the start and stop points are positioned on the perimeter for straightforward tool path generation, then the processing is simpler, but porosity and sealing issues occur at the intersection points
Solution Approach 1:
The patent applies local quality by differentiating the treatment of different regions within the layer. Instead of uniformly positioning start and stop points on the perimeter for all contours, the method specifically identifies interior regions and positions start/stop points within those regions for contours where this would prevent porosity and sealing issues. This localized adjustment maintains simplicity where not needed while improving reliability where problems occur.
3Device complexity
If contour tool paths are generated with start and stop points on the exterior perimeter, then the tool path generation is more straightforward, but the resulting model exhibits visible seams and surface irregularities
Solution Approach 1:
The host computer performs preliminary action by automatically calculating and adjusting the start and stop point positions within interior regions before generating the final tool path data. This pre-processing step modifies the contour tool paths to ensure seams form inside the model, thereby preventing surface irregularities without requiring complex manual intervention or post-processing corrections.
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
The method effectively conceals seams by masking variations in the extrusion process within the model's interior, resulting in consistent dimensions and reduced porosity, thus improving the overall quality of the 3D models.
Implementation Method 1
an extrusion-based digital manufacturing system that builds a 3D model from a digital representation of the 3D model in a layer-by-layer manner by extruding a flowable consumable modeling material
Implementation Method 2
The extruded modeling material fuses to previously deposited modeling material, and solidifies upon a drop in temperature
Data Source
AI summary
A three-dimensional model built with an extrusion-based digital manufacturing system, and having a perimeter based on a contour tool path that defines an interior region of a layer of the three-dimensional model, where at least one of a start point and a stop point of the contour tool path is located within the interior region of the layer.