Co-Extruded Wire Anchoring for Automated LFPAM Toolpaths
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Solution Overview
Problem
Existing large-format polymer additive manufacturing (LFPAM) methods face challenges in embedding metallic wires within polymer structures for self-heating molds and dies, particularly for complex geometries, due to manual pathing processes that are time-consuming and inefficient.
Innovation Solution
Automated methods and systems for embedding metallic wires using large-format polymer additive manufacturing (LFPAM) that include memory encoding instructions for precise wire placement, Boolean operations, and path generation algorithms to ensure proper alignment and tensioning, enabling automated generation of pathing for complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual pathing is used for embedding wires in additive manufacturing, then wire placement can be achieved for simple geometries, but the process becomes time-consuming and inefficient for complex geometries
Solution Approach 1:
The patent replaces manual mechanical pathing operations with an automated computer system that generates wire paths algorithmically. The system uses software to automatically determine optimal wire routing through complex geometries, eliminating the need for manual intervention and significantly reducing pathing time while maintaining precision.
Solution Approach 2:
The additive manufacturing system performs wire path generation autonomously without external manual input. The automated system takes the 3D model as input and independently generates the complete wire embedding path, allowing the manufacturing process to serve itself rather than requiring continuous human guidance.
2Adaptability or versatility
If co-extrusion systems are used for wire embedding, then self-heating molds can be produced, but the manual toolpath modification process is not practical for most large-scale molds and dies
Solution Approach 1:
The patent replaces manual toolpath modification processes with automated computer-generated wire paths. The system automatically adapts the co-extrusion process to complex large-scale mold geometries, eliminating the impractical manual adjustments and enabling efficient production of versatile self-heating molds and dies.
3Productivity
If automated wire path generation is implemented, then manufacturing efficiency improves, but computational complexity increases
Solution Approach 1:
The patent employs a computer-based automated system that uses algorithms to generate wire paths efficiently. While the computational system adds complexity, it replaces numerous manual operations, resulting in net productivity improvement. The computational complexity is managed through software automation that handles path generation, tensioning calculations, and anchor placement systematically.
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
Facilitates efficient and precise embedding of metallic wires within polymer structures, reducing manual intervention and enabling the production of complex self-heating molds and dies with embedded heating elements, thus reducing costs associated with thermal ovens.
Implementation Method 1
co-extrusion printing processes to facilitate mold or die heating
Implementation Method 2
The embedded wire can be connected to a power supply to heat the mold or die internally
Data Source
AI summary
Methods and apparatus for embedding metallic wires within polymer structures through co-extrusion printing in large-format polymer additive manufacturing (LFPAM). The method includes receiving user input for object and wire regions, performing Boolean operations on the meshes, generating printing paths, and determining an optimized order for printing. The LFPAM tool, configured with a data processing apparatus, prints the object with embedded wire and anchors supporting the wire ends. The system may include the use of a cutting tool to separate the anchors from the printed object. This disclosure improves wire alignment, support, and printing performance, enhancing the properties of wire-embedded printed structures.