Additive Manufacturing Tool Paths Using Intermediate Slicing Layers
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Solution Overview
Problem
Existing processes for generating tool path data in additive manufacturing fail to utilize the full resolution of the additive manufacturing apparatus, resulting in inferior material and structural properties, and are computationally intensive, especially for objects with fine or complex structural features.
Innovation Solution
A computer-implemented method that generates tool path data by using an intermediate slicing layer between physical build layers, projecting intermediate layer points to projected build layer points, and utilizing these points to create tool path data that better represents the desired object structure, thereby improving resolution and reducing computational intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing processes generate tool path data by slicing only at physical build layers, then the process is simpler and computationally less intensive, but the full resolution of the additive manufacturing apparatus is not utilized and material/structural properties are inferior
Solution Approach 1:
The patent divides the build space into multiple intermediate slicing layers between physical build layers. This segmentation allows the tool path to be generated at higher resolution intervals, capturing fine structural features while maintaining computational manageability through systematic layer division.
Solution Approach 2:
The patent introduces an intermediate dimension by placing slicing layers between the standard physical build layers. This additional dimensional layering enables finer resolution in the Z-direction without requiring more physical layers, thus improving manufacturing precision while managing computational complexity.
2Measurement precision
If existing processes generate tool path data using volumetric representation with closed contours, then the process is straightforward, but it is extremely computationally intensive for objects with fine or complex structural features
Solution Approach 1:
The patent extracts only the essential line representations from volumetric data, eliminating the need to process complete closed contours. This extraction approach maintains sufficient geometric accuracy for tool path generation while dramatically reducing computational requirements.
Solution Approach 2:
Instead of generating closed contours from volumetric data and then slicing, the patent inverts the approach by directly slicing line representations at intermediate layers. This inversion simplifies the data processing pipeline and reduces computational intensity while maintaining representation accuracy.
3Manufacturing precision
If existing processes use standard physical build layers only, then the apparatus operates at its base resolution, but finer detail and superior material properties cannot be achieved
Solution Approach 1:
The patent performs preliminary slicing at intermediate layers before final tool path generation. This preliminary action at higher resolution intervals prepares the data structure to capture fine details, enabling the apparatus to achieve finer detail and superior material properties without increasing physical layer complexity.
Data Source
AI summary
Generating tool path data for an additive manufacturing apparatus comprises providing object design data in which at least a part of a physical object is represented by a line. A section of the line is then sliced using an intermediate slicing layer that is provided between first and second physical build layers of the additive manufacturing apparatus. The slicing generates an intermediate layer point at the intersection of the section of the line and the intermediate slicing layer, with the intermediate layer point being located between the first and second physical build layers. The intermediate layer point is then projected to a projected build layer point that lies within a physical build layer of the additive manufacturing apparatus. The projected build layer point is used to provide tool path data for that physical build layer. A similar process can be used in which the physical object is represented by a surface.