3D Printing Toolpath Bridges for Continuous Layer Deposition
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Solution Overview
Problem
Conventional additive manufacturing techniques face inefficiencies due to isolated paths in toolpaths, leading to increased deposition time, material issues, and printing failures, as the printer slows down, stops, and restarts frequently, causing imperfect deposition and potential printing failures.
Innovation Solution
The system and method introduce bridge connections between isolated paths in toolpaths to create continuous, Eulerian layers, reducing deposition time by eliminating empty travel and ensuring non-stop deposition, with bridge connections restricted to areas covered by the base toolpath and strategically placed to minimize extrusion speed during bridging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional isolated path toolpaths are used, then the printer can follow standard slicing software instructions, but deposition time increases significantly due to frequent stops and starts
Solution Approach 1:
The patent applies continuity of useful action by transforming disconnected isolated paths into a continuous toolpath using bridge connections. The bridge paths connect endpoints of isolated paths, allowing the printer to deposit material continuously without stopping or traveling empty between paths. This eliminates the cycle of slowing down, stopping deposition, empty travel, and restarting deposition, thereby maintaining continuous useful action throughout the printing process.
Solution Approach 2:
The patent uses bridge connections as intermediary elements that mediate between isolated paths. These bridge paths serve as connecting structures that link previously disconnected path segments, enabling the printer to transition smoothly from one isolated path to another without empty travel. The bridge connections act as intermediaries that facilitate continuous material deposition across the entire infill area.
2Manufacturing precision
If frequent stops and starts are made during deposition, then isolated paths can be printed individually, but material deposition quality deteriorates due to dragging and oozing
Solution Approach 1:
The patent eliminates the discontinuous stop-start-deposit cycle by implementing continuous toolpaths with bridge connections. The printer maintains constant material deposition throughout the printing process, moving smoothly from one path segment to another through bridge connections without stopping. This continuous deposition prevents material dragging at path endpoints and unwanted oozing during empty travel, significantly improving deposition quality.
3Area of stationary object
If the number of disconnected paths is increased, then infill pattern coverage is improved, but total deposition time increases significantly
Solution Approach 1:
The patent merges multiple disconnected isolated paths into a unified continuous toolpath system. By introducing bridge connections that link the endpoints of various infill paths, the system combines what were previously separate printing operations into a single continuous deposition process. This merging allows the printer to cover the same infill area through multiple paths without the penalty of repeated stops and empty travels between them.
Data Source
AI summary
A system and method for improving additive manufacturing, including additive manufacturing toolpaths, is provided. The system and method includes a toolpath generator that obtains initial toolpaths of an object, identifies isolated paths in the toolpaths, and adds bridge connections between neighboring isolated paths in each layer to improve the toolpaths. The bridge connections facilitate the continuous and non-stop deposition of each layer according to improved toolpaths during additive manufacture, which can reduce total deposition time and improve the resultant additive manufacture.