Variable Width Brim for Additive Manufacturing Warp Prevention
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Solution Overview
Problem
Current FFF 3D printing techniques often result in warped parts due to the cooling and solidification of liquefied extrusion material, especially at convex corners, which becomes more pronounced as part size increases, and existing methods for warp prevention require additional filament and manual design efforts.
Innovation Solution
A system that generates a variable width brim for the first layer of a 3D model, where the brim width varies based on the convexity of the model's regions, using a weighted average of angles between discrete points to determine the brim width, and can include a perforated edge, to provide extra adhesion and prevent warping without unnecessary filament usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a uniform brim is added around the entire first layer to prevent warping, then warping at convex corners is reduced, but filament usage and printing time increase unnecessarily in non-convex regions
Solution Approach 1:
The brim width is varied locally based on the convexity of each region. Convex corners receive wider brim segments for enhanced adhesion and warp prevention, while non-convex regions use minimal or no brim extension. This localized adaptation ensures warp prevention where needed while minimizing unnecessary filament usage in regions that don't require additional support.
Solution Approach 2:
The brim is divided into multiple segments corresponding to different regions of the first layer. Each segment's width is independently calculated based on the convexity characteristics of its associated region. This segmentation allows the system to apply different brim widths to different parts of the model, optimizing both warp prevention and material efficiency.
2Reliability
If extra extrusion material is added around the part to hold down the first few layers, then warping is reduced, but the complexity of the printing process increases
Solution Approach 1:
The system automatically analyzes the 3D model's geometry to identify convex regions and calculate the optimal brim width for each segment. This self-service approach eliminates the need for manual intervention or complex user configuration, as the system autonomously determines the appropriate brim configuration based on the model's characteristics alone.
Solution Approach 2:
The brim width parameter is dynamically adjusted based on the convexity parameter of each region. By changing the brim width parameter locally rather than applying a uniform value, the system achieves effective warp prevention with a simple automated calculation process, avoiding the need for complex manual procedures.
3Ease of operation
If a perforated edge is created in the brim, then adhesion is maintained while ease of part removal is improved
Solution Approach 1:
The brim's edge is segmented into solid and perforated sections. The perforations are strategically placed to create separation points that facilitate easy removal of the brim from the printed part. The solid portions maintain sufficient adhesion strength during printing, while the perforated sections allow the brim to be cleanly separated from the part after printing without damaging either the part or the build plate.
Data Source
AI summary
Methods, systems, and apparatus, including medium-encoded computer program products, for reducing or eliminating curl and wrap in additive manufacturing include, in at least one aspect, obtaining a three dimensional (3D) model of a 3D object to be additively manufactured using a thermoplastic material delivery apparatus; generating a variable width brim for at least a first layer of the 3D model, wherein a width of the brim varies from a maximum value to a minimum value at different locations adjacent at least the first layer of the 3D model, and the generating comprises varying the width of the brim in accordance with an amount of convexity of the 3D model in regions corresponding to the different locations; and outputting the variable width brim for use in preventing warping during the additive manufacturing of the object from the 3D model using the thermoplastic material delivery apparatus.