Sectioned 3D Printing Parameters for Large-Part Layer Fusion
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Solution Overview
Problem
Traditional 3D printing methods using molten thermoplastic materials are inefficient for manufacturing large or complex parts due to the need for constant print parameters across all layers, which limits optimization and increases production time.
Innovation Solution
The method involves dividing a CAD model into sections with unique print parameters for each layer, allowing for varying print parameters across different sections of a part, enabling optimized layer-by-layer printing and improved fusion of sections during the additive manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If constant print parameters are used across all layers, then the printing process is simple to control, but production time increases and efficiency decreases
Solution Approach 1:
The patent divides the printing process into multiple sections, each with its own optimized print parameters. The controller is configured to receive model data divided into multiple sections, where each section has unique print parameters optimized for specific geometric features or material requirements. This segmentation allows different parts of the model to be printed with tailored parameters, improving overall productivity without requiring complete redesign of the control system.
Solution Approach 2:
The patent implements dynamic parameter adjustment during the printing process by transitioning from static, constant print parameters to dynamic, section-specific parameters. The controller automatically switches between different parameter sets based on the current printing section, enabling adaptive optimization of print speed, temperature, and other parameters for each section while maintaining systematic control.
2Manufacturing precision
If section-specific print parameters are used, then printing efficiency and quality improve, but the complexity of parameter management increases
Solution Approach 1:
The model data is segmented into multiple sections, each associated with specific geometric features or material properties. This segmentation enables precise control of print parameters for each section, improving layer fusion quality and manufacturing precision. The controller manages these segmented sections systematically, reducing the perceived complexity through automated parameter assignment based on section characteristics.
Solution Approach 2:
The patent applies the principle of local quality by assigning unique print parameters to specific sections of the model based on their local geometric features or material requirements. Each section can have optimized parameters for its specific needs, such as different print speeds, temperatures, or layer heights, thereby improving overall manufacturing precision without requiring uniform parameters across the entire model.
3Loss of time
If traditional layer-by-layer printing with constant parameters is used, then the process is straightforward, but production time for large or complex parts increases significantly
Solution Approach 1:
By dividing the model into multiple sections with unique print parameters, the system can optimize printing speed and quality for each section independently. This segmentation enables faster printing of less critical sections while maintaining high quality for critical sections, thereby reducing overall production time for large or complex parts without sacrificing adaptability.
Solution Approach 2:
The patent implements parameter changes by allowing different print parameters (such as temperature, speed, layer height) to be applied to different sections of the model. This versatility enables the system to adapt to varying requirements across different parts of the model, optimizing both production time and print quality through parameter variation rather than using constant parameters throughout.
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 the efficiency of the 3D printing process by allowing for optimized print parameters in different sections of a part, reducing production time and improving the quality of the final product by enabling better control over layer fusion and part geometry.
Implementation Method 1
melting a thin layer of thermoplastic material, and applying this material in layers
Implementation Method 2
Friction from the rotating screw, combined with heat from the barrel may soften the thermoplastic material
Implementation Method 3
heat from the barrel may soften the thermoplastic material
Implementation Method 4
The melted thermoplastic material may be applied to the existing structure in layers, melting and fusing with the existing material
Data Source
AI summary
A method of forming a part using additive manufacturing may include receiving, at a computer numeric controlled (CNC) machine, a computer aided design (CAD) model of the part. The method may further include dividing the CAD model into plurality of sections. The method may further include slicing each of the plurality of sections into a plurality of layers. Each section may include a distinct set of print parameters. The method may further include depositing a flowable material onto a worktable according the set of print parameters for each section of the of the plurality of sections to manufacture the part.