Tool-Path Analysis Mesh Generation for Accurate 3D Print Simulation

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Solution Overview

Problem

Existing methods for generating analysis meshes for 3D printing simulations often result in errors between tool path data and finite elements, leading to incorrect placement of finite elements during the modeling process, causing deformation and anisotropy issues in the final product.

Innovation Solution

An analysis mesh generation method that inputs tool path data, defines an initial mesh of microelements encompassing the tool path, determines overlap, removes non-overlapping microelements, and stores associations with overlapping microelements, considering the width and thickness of the tool path, and includes attributes such as material supply order and temperature.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If analysis mesh is generated from outer shape file independently of tool path data, then mesh generation can be performed, but errors occur between analysis mesh and tool path data causing incorrect finite element placement

Engineering Contradiction:

Improvepositioning accuracy of finite elementsVSAvoidcomplexity of data generation process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention applies preliminary action by generating the analysis mesh using tool path data as the basis before simulation execution. The mesh generation process incorporates tool path information in advance, ensuring that finite elements are positioned according to actual material deposition locations. This preliminary alignment prevents positioning errors that would otherwise occur when generating mesh independently from outer shape files.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention merges tool path data and analysis mesh generation into a unified process. Instead of treating them as separate operations that may produce inconsistencies, the method combines them so that the analysis mesh is constructed directly from tool path information. This merging ensures that the finite element positions accurately reflect the actual tool path trajectory and material deposition patterns.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If tool path data and analysis mesh are generated separately from outer shape, then both data types can be obtained, but positional errors occur where finite elements do not align with tool path

Engineering Contradiction:

Improveaccuracy of simulation resultsVSAvoidtime for data processing and correction

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The invention performs preliminary alignment by generating the analysis mesh concurrently with tool path data extraction. The mesh generation process uses tool path information as input, ensuring that finite elements are positioned at correct locations before simulation begins. This eliminates the need for subsequent time-consuming adjustments and corrections that would be required if errors were detected after separate generation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention implements feedback by using tool path data to guide and validate the analysis mesh generation process. The system continuously references tool path positions during mesh creation, ensuring that each finite element's position is verified against actual tool trajectory. This feedback mechanism prevents positional errors from occurring in the first place, rather than requiring post-processing corrections.

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If analysis mesh includes all microelements from outer shape, then complete coverage is achieved, but non-overlapping elements cause errors where no finite elements exist at tool path locations

Engineering Contradiction:

Improvealignment between mesh and tool pathVSAvoidnumber of finite elements

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The invention extracts only the necessary finite elements by removing non-overlapping microelements from the initial mesh. Instead of using all possible elements from outer shape decomposition, the method selectively retains only those elements that correspond to actual tool path positions. This extraction process eliminates erroneous gaps where no finite elements would exist at tool path locations, while reducing the total number of elements to only those needed for accurate simulation.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS11416655B2Analysis mesh generation method, recording medium, and analysis mesh generation device

Publication Date: 2022.08.16 TORAY ENG CO LTD

AI summary

An analysis mesh generation method is used for a modeling simulation of an article modeled according to a tool path. The method comprises: inputting the tool path for a product to be analyzed; defining an initial mesh that is made up of a number of microelements and encompasses the tool path; and determining overlap between the tool path and the microelements, removing non-overlapping microelements from the initial mesh, and storing an association of the tool path with overlapping microelements.