3D Part Strain Orientation for Additive Manufacturing

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Solution Overview

Problem

Additive manufacturing techniques face limitations in achieving high interlayer strengths in 3D parts, as the layer-by-layer process often aligns high tensile strains with weaker interlayer bonds, leading to potential failure under tensile stresses.

Innovation Solution

The method involves generating strain data from digital models using finite element analysis and orienting the models to align directions of high tensile strain within the build plane, directing these strains against the higher intralayer strengths, thereby enhancing the part's structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the digital model is oriented to align high tensile strain directions in the build plane, then the strength of the 3D part is improved, but the build time and material consumption increase

Engineering Contradiction:

Improvepart strengthVSAvoidbuild time

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent performs finite element analysis and determines optimal orientation of the digital model before the additive manufacturing process begins. By pre-calculating the strain directions and orienting the model accordingly, the system prepares the part in advance to maximize strength without requiring real-time adjustments during printing, thus minimizing the impact on build time.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the orientation parameter of the digital model based on strain analysis results. By rotating or repositioning the model in the build plane to align high tensile strain directions with the x and y axes, the system optimizes the part's strength characteristics while maintaining the same manufacturing process parameters.

Inventive Principle:

Principle #35Parameter changes

2Strength

If the digital model is oriented to align high tensile strain directions in the build plane, then the strength of the 3D part is improved, but the material consumption increases

Engineering Contradiction:

Improvepart strengthVSAvoidmaterial consumption

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The system performs strain analysis and determines optimal orientation before manufacturing, allowing the model to be pre-positioned to maximize strength. This preliminary optimization ensures that material is distributed most efficiently in high-stress areas, reducing overall material consumption while maintaining or improving part strength.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If finite element analysis is performed on the digital model to generate strain data, then the manufacturing precision is improved, but the device complexity increases

Engineering Contradiction:

Improveorientation precisionVSAvoidsystem complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces physical trial-and-error orientation methods with computational finite element analysis. By using software-based strain calculation and automated orientation determination, the system achieves high manufacturing precision without requiring complex physical testing apparatus or multiple manufacturing iterations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9925725B2Method for printing three-dimensional parts with part strain orientation

Publication Date: 2018.03.27 STRATASYS INC

AI summary

A method and program for printing a three-dimensional part with an additive manufacturing system, the method including generating or otherwise providing strain data from a digital model of the three-dimensional part, orienting the digital model to align the directions of high tensile strain in a build plane, and printing the three-dimensional part in a layer-by-layer manner based on the oriented digital model with the additive manufacturing system.