3D Printing Void Filling via Remnant Path Segmentation
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Solution Overview
Problem
Extrusion-based layered deposition systems face issues with small void regions in 3D object fabrication, leading to increased porosity and reduced structural integrity and sealing properties due to the reliance on constant road width resolutions that ignore voids smaller than the resolution.
Innovation Solution
Generating build paths that include remnant paths with varying widths to fill void regions, using intermediate paths to calculate and adjust deposition rates based on void widths, ensuring the build material fills the voids without compromising layer thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If constant road width resolution is used to generate build paths, then productivity is improved through rapid data generation and deposition, but manufacturing precision deteriorates due to small void regions being ignored
Solution Approach 1:
The patent segments the build path generation process into multiple stages: initial build path generation using constant road width resolution, identification of void regions, and subsequent remnant path generation specifically targeting void regions. This segmentation allows different resolution strategies to be applied to different areas, maintaining productivity while improving precision in critical void regions.
Solution Approach 2:
The patent applies local quality by using high road width resolution specifically in void regions where precision is critical, while using constant road width resolution in other areas to maintain productivity. The remnant paths are generated with varying widths tailored to the specific geometry of each void region, ensuring precise filling where needed without compromising overall build speed.
2Device complexity
If constant road width resolution is used, then device complexity is reduced through simplified path generation algorithms, but manufacturing precision deteriorates due to inability to address varying void widths
Solution Approach 1:
The algorithm is segmented into two parts: a simple initial build path generation using constant road width resolution, and a more complex remnant path generation phase that specifically addresses void regions. This segmentation keeps the overall system manageable while improving precision in critical areas.
Solution Approach 2:
The patent performs preliminary action by first generating the initial build path and identifying void regions before generating the remnant paths. This preliminary identification allows the system to prepare targeted high-resolution paths for void regions without requiring the entire system to operate at high complexity from the start.
3Manufacturing precision
If remnant paths with varying widths are generated to fill void regions, then manufacturing precision is improved by reducing porosity, but device complexity increases due to additional path generation steps
Solution Approach 1:
The patent applies local quality by generating remnant paths with varying widths specifically tailored to the geometry of void regions, ensuring precise filling and porosity reduction only where needed. This localized approach improves manufacturing precision in critical areas without requiring the entire build path generation system to become overly complex.
Solution Approach 2:
The system performs preliminary identification and characterization of void regions before generating remnant paths. This preliminary action allows the complex remnant path generation to be targeted and efficient, reducing the overall complexity burden by preparing the necessary information in advance.
4Manufacturing precision
If remnant paths are generated based on intermediate paths, then manufacturing precision is improved through accurate void region filling, but loss of time increases due to additional computation and deposition steps
Solution Approach 1:
The patent segments the path generation into efficient initial build path creation and targeted remnant path generation for void regions. This segmentation ensures that the additional time for high-precision void filling is minimized by only applying detailed processing where necessary, rather than to the entire build volume.
Solution Approach 2:
The system performs preliminary identification of void regions and generation of intermediate paths before creating final remnant paths. This preliminary action optimizes the subsequent remnant path generation by pre-processing the void region data, reducing the computational burden and deposition time during the final high-precision filling phase.
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 effectively reduces porosity and maintains structural integrity and sealing properties by filling voids with varying deposition rates, ensuring uniform layer thickness and improved material properties.
Implementation Method 1
The build material is extruded through a nozzle carried by an extrusion head, and is deposited as a sequence of roads on a base in an x-y plane
Implementation Method 2
The extruded build material fuses to previously deposited build material
Implementation Method 3
solidifies upon a drop in temperature
Data Source
Figure 1
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AI summary
A method of forming a three-dimensional object using an extrusion- based layered deposition system, the method comprising generating a build path (10) for building a layer of the three-dimensional object, where the build path (10) defines a void region (20). The method further comprising generating at least one intermediate path in the void region (20), and generating a remnant path (21 ) based at least in part on the at least one intermediate path.