Additive Manufacturing Toolpaths Aligned to Mechanical Stress
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Solution Overview
Problem
Additive manufacturing systems do not adequately account for mechanical stress and anisotropic variations during the manufacturing phase, leading to inconsistent structural integrity in load-bearing structures.
Innovation Solution
Control toolpaths by specifying desired manufacturing paths that align with expected mechanical stress and material properties, using guide curves or surface sequences to generate manufacturing control instructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional additive manufacturing toolpaths are used, then manufacturing simplicity is maintained, but structural integrity under mechanical stress deteriorates
Solution Approach 1:
The patent applies preliminary action by determining desired manufacturing paths before actual manufacturing occurs. The system receives indication of desired manufacturing paths that align with expected mechanical stress directions, then uses these pre-determined paths to generate toolpath control instructions. This allows the manufacturing process to be optimized for structural integrity from the outset rather than requiring complex real-time adjustments during manufacturing.
Solution Approach 2:
The patent implements local quality by varying the manufacturing path orientation according to the local stress conditions at different locations of the structural object. Different sections of the object receive manufacturing paths specifically aligned with the expected mechanical stress in that particular region, ensuring that fiber reinforcement and layer bonding are optimized for the specific load conditions each area will experience.
2Reliability
If manufacturing paths are aligned with mechanical stress, then structural integrity improves, but manufacturing process complexity increases
Solution Approach 1:
The patent applies parameter changes by modifying the manufacturing path parameters (direction, orientation, sequence) based on the expected mechanical stress characteristics. The system receives indication of desired manufacturing paths that incorporate stress alignment parameters, then generates toolpath control instructions that implement these parameter adjustments. This allows optimization of structural performance through controlled variation of manufacturing parameters rather than complex mechanical modifications.
3Strength
If fiber orientation is controlled to match stress directions, then tensile strength increases, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-determining the optimal fiber orientation paths before manufacturing. The system receives indication of desired manufacturing paths that are aligned with expected mechanical stress directions, allowing the fiber reinforcement to be strategically oriented in advance. This pre-planning ensures that fibers are deposited in the most effective orientations for resisting applied loads without requiring complex real-time precision control during the manufacturing process.
Data Source
AI summary
Aspects are described for use in additive manufacturing. A desired manufacturing path may be specified for a 3D model of an object to manufacture via additive manufacturing. The object may be a load-bearing structure. The desired manufacturing path may be based on the expected mechanical stress on the object. Slicing the 3D model may provide toolpath segments corresponding to a toolpath of an additive manufacturing apparatus. The toolpath segments may be sorted and oriented based on the desired manufacturing paths. Additive manufacturing control instructions may be generated based on the sorted and oriented toolpath segments. The additive manufacturing control instructions may be used to control the toolpath of an additive manufacturing apparatus in accordance with the desired manufacturing paths when manufacturing the object via an additive manufacturing process.