Variable Bead Size Control for Accurate 3D Printed Layers
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Solution Overview
Problem
In additive manufacturing, existing systems face challenges in achieving geometrical accuracy due to uniform bead sizes, leading to over- or under-deposition of material, which cannot be corrected after the deposition process has started.
Innovation Solution
A data processing system that varies bead sizes along toolpaths by generating pixel values for bead size images, allowing for proactive adjustment of process parameters such as laser power and nozzle speed to match the required bead sizes, thereby minimizing material deposition errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If uniform bead size is used along the toolpath, then the additive manufacturing process is simple to control, but geometrical accuracy deteriorates due to over- or under-deposition of material
Solution Approach 1:
The patent applies local quality by varying bead size according to the local geometric characteristics of the toolpath. The system calculates the curvature radius at each point along the toolpath and adjusts the bead size locally - using smaller beads in high-curvature regions and larger beads in low-curvature regions. This localized adaptation ensures geometrical accuracy without requiring complex global process changes
Solution Approach 2:
The patent implements dynamics by making the bead size variable rather than fixed. The system dynamically adjusts the bead size parameter along the toolpath based on real-time curvature calculations. The bead size becomes a dynamic parameter that changes continuously with the toolpath geometry, allowing the process to adapt to varying geometric requirements
2Manufacturing precision
If default bead size is used for all locations, then the processing is consistent and simple, but material deposition accuracy worsens at locations with different curvature requirements
Solution Approach 1:
The patent applies preliminary action by pre-calculating the optimal bead size for each location along the toolpath before the actual additive manufacturing process. The system performs curvature analysis and generates a bead size distribution map in advance, so that when deposition begins, the appropriate bead size is already determined for each segment, eliminating the need for complex real-time adjustments during operation
Data Source
AI summary
A system may include a processor configured to receive toolpaths along which a 3D printer deposits beads of material in a plurality of layers in order to additively build up a product. Based on the toolpaths, the processor may determine an image for each layer and may process the images based on a default bead size to determine a bead size image for each layer comprised of pixels having values that specify bead size for locations along the toolpaths. The image processing produces pixel values for the bead size images that vary in magnitude at different locations along the toolpaths in order to represent smaller and larger bead sizes relative to the default bead size, which smaller and larger bead sizes respectively minimize over-depositing and under-depositing of material by the 3D printer that would otherwise occur with the default bead size.