Additive Manufacturing Tool Paths With Tangent Arc Corner Compensation
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Solution Overview
Problem
Additive manufacturing processes, particularly 3D printing, suffer from material distortion when transitioning corners due to the offset between the compression roller and extrusion nozzle, which is not compensated for by existing CNC tool-path generating software.
Innovation Solution
Introduce a tangent arc into the tool path program to divert the material flow slightly outward before a directional change, compensating for the anticipated material pull-back during tool path changes exceeding a predetermined angle, thereby preventing distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a compression roller is used to flatten and fuse deposited material layers, then manufacturing efficiency and material fusion are improved, but material distortion occurs at directional changes due to the offset between the roller and extrusion nozzle
Solution Approach 1:
The system performs preliminary assessment of the tool path to identify upcoming directional changes, and preemptively adds tangent arcs to the tool path before the actual direction change occurs. This preliminary action compensates for the material distortion that would otherwise be caused by the compression roller offset, allowing the roller to flatten and fuse material effectively while maintaining dimensional accuracy.
Solution Approach 2:
The system modifies the tool path parameters by adding tangent arcs with specific radii and positions based on the detected directional changes. This parameter adjustment changes the deposition pattern to compensate for the compression roller's offset, transforming the tool path from a simple linear sequence to one that includes compensatory curved segments.
2Device complexity
If the tool path follows a straight line with sharp directional changes, then manufacturing simplicity is maintained, but material distortion and deformation occur at corners
Solution Approach 1:
The control system assesses the tool path in advance to identify sharp directional changes, and automatically adds tangent arcs to compensate before the direction change occurs. This preliminary assessment and modification maintains tool path simplicity from the user perspective while internally adding the necessary compensatory geometry to prevent material distortion.
Solution Approach 2:
The tangent arc acts as an intermediary element between the original sharp corner and the final deposited material. Instead of directly changing direction at a sharp corner, the tool path introduces a intermediate curved segment that allows the compression roller to gradually transition, preventing the material distortion that would occur with an abrupt direction change.
3Adaptability or versatility
If existing CNC tool-path generating software is used without modification, then software compatibility is maintained, but material distortion at directional changes is not compensated
Solution Approach 1:
The control system continuously monitors and assesses the tool path for directional changes, and provides feedback by automatically modifying the tool path to add tangent arcs. This feedback loop ensures that the tool path is adaptively adjusted in real-time to compensate for compression roller effects, while maintaining compatibility with existing CNC software architectures.
Solution Approach 2:
The control system performs multiple functions: it generates or imports tool paths from existing CNC software, assesses the tool path for directional changes, modifies the tool path by adding tangent arcs, and controls the additive manufacturing process. This multi-functionality allows the system to maintain software compatibility while adding intelligent compensation capabilities.
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 method effectively reduces or eliminates material distortion by pre-emptively adjusting the tool path, ensuring accurate and usable components are produced.
Implementation Method 1
comprises a process of melting a thin layer of a flowable material (e.g., a thermoplastic material), and applying this material in layers to produce a final part
Implementation Method 2
The heated material is applied to the existing structure in thin layers, melting and fusing with the existing material to produce a solid finished product
Implementation Method 3
The compression roller may be mounted in or on a rotatable carrier, which may be operable to maintain the roller in an orientation tangential, e.g., perpendicular, to the deposited material (e.g., bead or beads of thermoplastic material). The flattening process may aid in fusing a new layer of the flowable material to the previously deposited layer
Data Source
AI summary
Embodiments of the present disclosure are drawn to additive manufacturing methods. An exemplary method may include generating a tool path for forming a component via additive manufacturing, and assessing the tool path to identify a change in direction. The method may also include determining if the change in direction exceeds a predetermined angle, and adding a tangent arc to the tool path before the change in direction if the change in direction exceeds the predetermined angle.