3D Printing Support Structure Region Expansion
Solution Overview
Problem
In three-dimensional shaped object manufacturing, the accuracy of the shaped object can be compromised due to missing parts in the support structure, which occurs when the movement path of the nozzle cannot be set as intended, especially when the support structure's shape and conditions are not adequately defined.
Innovation Solution
The method involves generating shaping data that specifies a contact layer and a non-contact layer within the support structure, with the data generation unit expanding the first region to the second region when the width of the first region is insufficient to ensure complete path data generation, thereby preventing missing parts in the support structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the support structure is formed with a narrow first region for the contact layer, then the precision of the shaped object is improved, but the nozzle movement path cannot be set as intended and parts of the support structure may be missing
Solution Approach 1:
The support structure is divided into two distinct regions: a first region for the contact layer that contacts the shaped object, and a second region for the non-contact layer. This segmentation allows the nozzle movement path to be optimized separately for each region, ensuring complete formation of the support structure while maintaining precision where it contacts the object.
Solution Approach 2:
The invention introduces a dimensional distinction by separating the support structure into contact and non-contact layers along the vertical dimension. This allows the narrow first region to maintain precision for object contact while the expanded second region ensures complete nozzle path coverage for structural reliability.
2Reliability
If the first region is expanded to the second region, then the path data generation is ensured and support structure completeness is improved, but the area of the contact layer increases
Solution Approach 1:
By segmenting the support structure into contact and non-contact regions, the invention allows selective expansion only in the non-contact second region. This ensures path data generation completeness without unnecessarily expanding the contact layer area, maintaining precision while ensuring reliability.
Solution Approach 2:
The invention applies different quality requirements to different regions: the first region (contact layer) maintains narrow dimensions for precision, while the second region (non-contact layer) is expanded to ensure complete nozzle path coverage. This local differentiation resolves the contradiction between area expansion and precision maintenance.
Data Source
AI summary
A three-dimensional shaped object manufacturing method includes: generating shaping data including path data; and shaping, based on the shaping data, a shaped object and a support structure. In at least one layer of the support structure, a contact layer in contact with the shaped object above or below the shaped object and a non-contact layer different from the contact layer are disposed adjacent to each other. The generating the shaping data includes a specifying step of specifying, based on shape data of the shaped object, a first region for shaping the contact layer and a second region for shaping the non-contact layer, as a support region, and a data generation step of generating the path data in the support region based on a path generation condition. In the data generation step, when a width of the specified first region is insufficient to generate the path data based on the path generation condition, the first region is expanded to the second region adjacent thereto to generate the path data in the first region.