Slicer Bead Sequencing for Uniform Layer Growth in 3D Printing
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Solution Overview
Problem
Conventional additive manufacturing methods face challenges in efficiently depositing different materials at varying locations, leading to uneven layer growth and quality issues, particularly in large-scale metal parts with complex geometries, and multi-robot systems suffer from collisions and inefficiencies due to lack of effective toolpath assignment strategies.
Innovation Solution
A computer-implemented system dynamically assigns toolpaths for a multi-robot system using machine intelligence and adaptive strategies, incorporating sensors to handle dynamic behaviors and minimize collisions, ensuring uniform layer growth by determining the sequence of depositing weld beads based on material properties and environmental feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different materials are deposited at varying locations using conventional additive manufacturing methods, then material diversity is achieved, but uneven layer growth and quality issues occur
Solution Approach 1:
The system assigns different toolpaths and deposition parameters to different locations based on material requirements. Each robot receives customized toolpath instructions that account for local material properties, allowing different materials to be deposited at varying locations while maintaining layer uniformity through location-specific control strategies
Solution Approach 2:
The system dynamically adjusts deposition parameters and toolpath sequences in real-time based on material type and location. The control system modifies deposition rates, layer thickness, and bead placement parameters dynamically to compensate for variations in material properties, ensuring uniform layer growth across diverse materials
2Productivity
If multi-robot systems are used to increase deposition rate, then productivity is improved, but collisions and inefficiencies occur due to lack of effective toolpath assignment
Solution Approach 1:
The system segments the build volume into distinct regions and assigns specific toolpaths to each robot based on spatial separation. The toolpath assignment strategy divides the deposition task into non-overlapping zones for each robot, preventing collisions while maximizing the utilization of multiple robots simultaneously
Solution Approach 2:
The system implements real-time monitoring and feedback mechanisms to track robot positions and adjust toolpath assignments dynamically. Sensors and control systems provide continuous feedback on robot locations and deposition progress, enabling the system to prevent collisions and optimize toolpath allocation as the build progresses
3Manufacturing precision
If toolpath assignment is optimized for uniform layer growth, then manufacturing precision is improved, but deposition rate decreases
Solution Approach 1:
The system performs preliminary analysis of material properties and build geometry before generating toolpaths. By pre-calculating optimal deposition sequences, layer thickness variations, and bead placement strategies for each material type, the system ensures uniform layer growth is built into the toolpath from the beginning, eliminating the need for slow corrective adjustments during deposition
4Ease of operation
If single-robot systems are used to simplify operation, then ease of operation is improved, but single point of failure reduces reliability
Solution Approach 1:
The system employs multiple robots with identical or similar capabilities that can perform the same deposition functions. Each robot is equipped with the same tooling and control interfaces, allowing any robot to take over another's task if a failure occurs, thus maintaining system reliability while preserving operational simplicity through standardized multi-functional units
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 solution enhances productivity, reliability, and deposition rate by optimizing task allocation in real-time, reducing production time and avoiding single points of failure, while maintaining build quality and scalability.
Implementation Method 1
wire-arc welding system configured to deposit at least a first weld bead
Implementation Method 2
depositing the first weld bead and the second weld bead
Data Source
AI summary
System and methods for additive manufacturing of a three-dimensional part. The methods comprising: obtaining, by the processor, different bead heights that are to be used during the additive manufacturing; determining, by the processor, an order in which beads are to be printed based on (i) a list of ordered Z values, (ii) bead bottom Z values, (iii) bead top Z values, (iv) bead centers of gravity, or any combination of (i)-(iv); and printing the beads in the determined order to additively manufacture the three-dimensional part.