3D Print Support Segmentation for Mold Lock Removal
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Solution Overview
Problem
Mold lock occurs in three-dimensional printing when rigid support structures become geometrically interlocked with the printed object, preventing physical removal, and existing methods lack efficient automated solutions for identifying and remedying this condition.
Innovation Solution
A method involving layer-by-layer two-dimensional analysis to identify unconstrained removal paths for support structures, applying modification rules to break support structures into removable pieces, and employing three-dimensional strategies for complex cases, ensuring aligned draw paths and subdividing mold locked regions to facilitate removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid support structures are used to provide physical support according to design rules, then structural support function is improved, but mold lock conditions occur preventing removal
Solution Approach 1:
The patent segments rigid support structures into modular components with standardized connection features. Support structures are divided into interchangeable segments that can be independently removed or replaced, transforming a monolithic rigid structure into a disassemblable system that maintains strength during operation but enables easy removal afterward.
Solution Approach 2:
The patent introduces dynamic characteristics to rigid support structures through movable connection elements and adjustable positioning mechanisms. These elements allow the support structure to transition from a fixed rigid state during operation to a flexible disassemblable state during removal, resolving the contradiction between structural integrity and ease of removal.
2Productivity
If automated identification and remediation of mold lock conditions is implemented, then productivity is improved, but computational complexity increases
Solution Approach 1:
The patent implements self-service through automated algorithms that independently identify mold lock conditions and apply remediation rules without human intervention. The system performs self-diagnosis of geometric interlocking issues and self-correction through automated support structure modification, eliminating manual analysis while managing computational complexity through rule-based decision-making.
Solution Approach 2:
The patent replaces manual mechanical analysis and remediation processes with computational algorithms. Instead of human operators visually inspecting and manually modifying support structures, automated software performs geometric analysis, identifies mold lock conditions, and applies remediation transformations, substituting human cognitive and manual labor with computational processes.
3Ease of operation
If support structures are broken into multiple independently removable pieces, then ease of removal is improved, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing complex support structures into standardized modular segments with uniform connection interfaces. This segmentation enables independent removal of individual pieces while maintaining overall structural integrity during printing. The modular design reduces removal complexity by creating consistent, predictable disassembly patterns despite the increased number of components.
Solution Approach 2:
The patent applies local quality by varying the degree of segmentation and connection rigidity at different locations within the support structure. Critical load-bearing regions maintain stronger, more permanent connections, while non-critical regions use weaker, easily removable connections. This localized differentiation optimizes both structural strength during printing and ease of removal for specific segments.
Data Source
AI summary
Mold lock is remediated by performing a layer-by-layer, two-dimensional analysis to identify unconstrained removal paths for any support structure or material within each two-dimensional layer, and then ensuring that aligned draw paths are present for all adjacent layers, all as more specifically described herein. Where locking conditions are identified, a sequence of modification rules are then applied, such as by breaking support structures into multiple, independently removable pieces. By addressing mold lock as a series of interrelated two-dimensional geometric problems, and reserving three-dimensional remediation strategies for more challenging, complex mold lock conditions, substantial advantages can accrue in terms of computational speed and efficiency.