Virtual Build Volume Evaluation for Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing techniques face challenges in achieving high dimensional accuracy and preventing deformation due to thermal interactions between objects during the solidification process, particularly when using fusing agents that absorb energy and cause nearby objects to reach their fusing temperature, leading to potential bulges or deformities.
Innovation Solution
A method for evaluating candidate virtual build volumes that allows for differential separation distances based on the intended manufacturing accuracy of object portions, where high accuracy parts are separated by a greater distance to prevent thermal interference, while allowing closer packing of other parts, optimizing the packing efficiency and minimizing the build volume height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If objects are packed closely together in the build volume, then productivity and packing density are improved, but thermal interference causes deformation and manufacturing precision deteriorates
Solution Approach 1:
The patent applies different separation distances to different objects or different regions of objects based on their specific manufacturing accuracy requirements. Critical objects or regions receive greater separation distances to prevent thermal interference, while non-critical objects can be packed more closely, thus resolving the contradiction between packing density and dimensional accuracy through localized quality control.
2Manufacturing precision
If greater separation distance is maintained between objects, then manufacturing precision and prevention of thermal interference are improved, but the build volume height increases and productivity decreases
Solution Approach 1:
Instead of uniformly increasing separation distances for all objects, the patent selectively applies greater separation only to objects or regions requiring high dimensional accuracy. This localized approach maintains manufacturing precision for critical components while minimizing the overall build volume height and preserving productivity for non-critical components.
3Ease of manufacture
If uniform separation distance is applied to all objects, then ease of manufacture is improved, but manufacturing precision for high accuracy parts deteriorates due to insufficient thermal isolation
Solution Approach 1:
The patent moves from uniform separation distance to localized differential separation distances, where each object or region receives the specific separation distance required for its manufacturing accuracy needs. This approach maintains ease of manufacture through automated evaluation and selection processes while significantly improving dimensional accuracy for high-precision components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures high dimensional accuracy of critical object portions by maintaining sufficient separation, allowing for increased packing density and faster build times by optimizing the arrangement of objects within the build volume, thereby preventing deformation and enhancing the overall manufacturing process.
Implementation Method 1
a fusing agent (also termed a 'coalescence agent' or 'coalescing agent') may be selectively distributed onto portions of a layer of build material... The fusing agent may have a composition which absorbs energy such that, when energy (for example, heat) is applied to the layer, the build material to which fusing agent has been applied heats up/melts, coalesces and solidifies
Implementation Method 2
Additive manufacturing techniques may generate a three-dimensional object through the solidification of a build material... build material may be supplied in a layer-wise manner and the solidification method may include heating the layers of build material to cause melting in selected regions
Data Source
AI summary
In an example, a tangible machine-readable medium stores instructions which, when executed by a processor, cause the processor to evaluate a plurality of possible object generation arrangements based on a default separation distance and an enhanced separation distance, wherein the enhanced separation distance is used to assess predefined object sub-portions.