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WO2024124355A1 - Procédé et système de fabrication de pièces à base de polymère entrelacé à l'aide d'une fabrication additive - Google Patents

Procédé et système de fabrication de pièces à base de polymère entrelacé à l'aide d'une fabrication additive Download PDF

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Publication number
WO2024124355A1
WO2024124355A1 PCT/CA2023/051678 CA2023051678W WO2024124355A1 WO 2024124355 A1 WO2024124355 A1 WO 2024124355A1 CA 2023051678 W CA2023051678 W CA 2023051678W WO 2024124355 A1 WO2024124355 A1 WO 2024124355A1
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WIPO (PCT)
Prior art keywords
toolpath
pattern
continuous
slice
printable
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PCT/CA2023/051678
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English (en)
Inventor
Ahmed Qureshi
Remy SAMSON
David NOBES
Pierre MERTINY
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University of Alberta
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University of Alberta
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Publication of WO2024124355A1 publication Critical patent/WO2024124355A1/fr
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/118—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing

Definitions

  • the present invention generally relates to additive manufacturing techniques. More particularly, disclosed embodiments relate to a method and system for manufacturing polymer-based parts using additive manufacturing using an interweave technique.
  • AM additive manufacturing
  • 3D printing is a fast-emerging field and may facilitate such production.
  • a challenge of AM focuses on manufacturing composite materials with less lead time, as well as improved mechanical and structural properties for the printed part.
  • Embodiments herein generally relate to a method and system for manufacturing polymer-based parts using additive manufacturing.
  • the disclosed method generally involves, initially, vertically slicing a computer model of the to-be-printed part into n horizontal cross-sectional layers. For each slice, a horizontal envelope is determined, and if concave, the envelope is then divided into a number of convex subareas based on the layer thickness of the deposited material. For each convex area or subarea, an overlapping and/or interweaving zig-zag toolpath with at least four paths per slice is computed. Each of the four paths is either offset from or is oriented in a different direction from at least one of the other paths. By dividing the horizontal envelope into multiple convex subareas, the continuity of the zig-zag path inside each convex subarea is guaranteed.
  • All the zig-zag paths are then linked together using a boundary layer as a direction.
  • the bridges between the zig-zag paths correspond to a portion of the boundary layer.
  • the bridges are offset from each other to avoid massive overlapping.
  • a “lower layers awareness” map is determined to avoid collision between the nozzle of the additive manufacturing (AM) system, and the previously deposited matrix. This map encodes the vertical motion of the nozzle according to the average height of material deposited in its close neighborhood.
  • a method for manufacturing a polymer-based part using additive manufacturing comprising: generating a plurality of horizontally sliced layers of a virtual three-dimensional (3D) part model, wherein the virtual 3D part model extends along a printing axis, and the horizontally sliced layers are defined in horizontal planes orthogonal to the printing axis, and wherein the plurality of horizontal layers extend, along the printing axis, between a first printable layer and a last printable layer; for each horizontal slice, determining one or more envelope boundaries, wherein the envelopes define at least one printable cross-sectional area, corresponding to a non-void area of the 3D part in that horizontal slice; for each horizontal slice, determining a slice-specific toolpath pattern, wherein each slice-specific toolpath pattern defines a continuous overlapped and interwoven toolpath pattern for that slice, and covering the printable area for that slice; and manufacturing the part by operating an additive manufacturing (AM) system according to the slice-specific toolpath
  • AM additive manufacturing
  • the AM system is configured to print in a first and a second toolpath printing direction.
  • the first and second toolpath directions are orthogonal to each other, along a horizontal slice plane.
  • the printing axis defines a vertical Z-axis
  • the first and second toolpath directions are defined in the X- and Y-axis directions.
  • determining the slice-specific toolpath pattern for a given horizontal slice comprises: in respect of the first toolpath direction, determining a corresponding first and second continuous toolpath pattern, each pattern comprising a zig-zag extending along the first toolpath direction and covering the printable cross-sectional area; in respect of the second toolpath direction, determining a corresponding first and second continuous toolpath pattern in the second toolpath direction, each pattern comprising a zig-zag extending along the second toolpath direction and covering the printable cross-sectional area; generating an overlaid toolpath pattern, the overlaid pattern comprising a superimposed overlaying of the toolpath patterns determined for each toolpath direction, wherein the toolpath patterns are overlaid, over each other, in a direction of the printing axis, and wherein the printable areas, represented in each toolpath pattern, are orientationally aligned; and generating one or more connective toolpaths that link between the overlaid toolpath patterns, to generate the slice-specific toolpath pattern, defining a continuous overlap
  • the second continuous toolpath pattern is offset relative to the first continuous toolpath pattern, wherein the offset is defined such that, when the second continuous toolpath pattern is overlaid, along the printing axis, over the first continuous toolpath pattern, the second pattern includes a zig-zag toolpath positioned between adjacent path lines of the first path zig-zag, when viewed along the printing axis.
  • the toolpaths are overlaid, along the printing axis, in the overlaid toolpath pattern, in accordance with the following overlaid order: (a) the first continuous toolpath determined for the first toolpath direction; (b) the first continuous toolpath determined for the second toolpath direction; (c) the second continuous toolpath determined for the first toolpath direction; and (d) the second continuous toolpath determined for the second toolpath direction, wherein (a) defines the lower-most toolpath, and (d) defines the upper-most toolpath, along the printing axis.
  • determining the corresponding first and second continuous toolpath patterns initially comprises: determining whether the at least one printable area, for the horizontal slice, is a concave or convex are, relative to the toolpath direction, wherein the printable area is a convex area if a continuous zig-zag toolpath is generatable, along the toolpath direction, within the printable area without any discontinuity zones, and wherein the printable area is a concave area if a continuous zig-zag toolpath is not generatable, along the toolpath direction, within the printable area, and based on the determination, determining the first and second continuous toolpath patterns.
  • determining the corresponding first and second continuous toolpath patterns further comprises: segmenting the concave area into two or more convex subareas relative to the toolpath direction; for each convex subarea, determining a first and second toolpath zig-zag pattern, along the printing direction; determining one or more first linking paths connecting between each of the first toolpath patterns, of each convex subarea, to generate the first continuous toolpath pattern; and determining one or more second linking paths connecting between each of the second toolpath patterns, of each convex subarea, to generate the second continuous toolpath pattern.
  • segmenting the concave area into two or more convex subareas comprises: superimposing a plurality of rays over the horizontal slice, each ray extending along the toolpath direction; in respect of each ray, determining the number of intersection points between the ray and the envelope for the horizontal layer; if the number of intersections is higher than two for a given ray, then in respect of that ray, identifying pairs of intersection points separated by an outside of the printable cross-sectional area; determining intermediate points that are equally distally spaced between each pair of intersection points; and linking, all intermediate points, aligned along a line orthogonal to the rays, to segment the concave area into multiple local convex subareas.
  • a boundary envelope will be concave in at least a first horizontal direction and in a second horizontal direction which is substantially at a right angle to the first horizontal direction.
  • Each concave boundary envelope is then divided into at least two convex subareas, resulting in four convex subareas which overlap.
  • the toolpath configuration comprises at least one boundary envelope layer.
  • the first to fourth paths are connected with a link path which preferably lies on a boundary envelope layer.
  • a system for manufacturing a polymer-based part using additive manufacturing comprising: a deposition assembly, of an additive manufacturing (AM) system, for extruding filament material to manufacture a 3D part component; and at least one processor coupled to the deposition assembly, and configured for to preform any or all of the above.
  • AM additive manufacturing
  • Figure 1 is an example system for additive manufacturing.
  • Figure 2 are example virtual or computerized three-dimensional (3D) models of a
  • Figure 3A is a process flow for an example method for additive manufacturing of polymer-based three-dimensional (3D) parts.
  • Figure 3B is a process flow for an example method for determining a slice-specific toolpath configuration for additive manufacturing.
  • Figure 4 is a horizontally sliced 3D part model of the example Stanford bunny and double nut structures.
  • Figure 5 is a horizontal cross-sectional slice of the double nut structure, showing internal and external boundaries.
  • Figure 6A is a horizontal cross-sectional slice of the Stanford bunny, showing a zigzagging toolpath along the X-axis direction.
  • Figure 6B is a horizontal cross-sectional slice of the Stanford bunny, showing one or more X-direction local convex subareas.
  • Figure 7A is a horizontal cross-sectional slice of the Stanford bunny, showing a zigzagging toolpath along the Y-axis direction.
  • Figure 7B is a horizontal cross-sectional slice of the Stanford bunny, showing one or more local Y-direction convex subareas.
  • Figure 8A is a horizontal cross-sectional slice of the double nut structure, showing one or more local X-direction convex subareas.
  • Figure 8B is a horizontal cross-sectional slice of the double nut structure, showing one or more local Y-direction convex subareas.
  • Figure 9A shows a horizontal cross-sectional slice of the Stanford bunny, and showing first and second zig-zagging toolpath configurations, oriented in the X-direction, within local convex subareas.
  • Figure 9B shows a horizontal cross-sectional slice of the Stanford bunny, and showing first and second zig-zagging toolpath configurations, oriented in the Y-direction, within local convex subareas.
  • Figure 10A shows a horizontal cross-sectional slice of the double nut structure, and showing first zig-zagging toolpath configurations, oriented in the X and Y directions, within local convex subareas.
  • Figure 10B shows a horizontal cross-sectional slice of the double nut structure, and showing second zig-zagging toolpath configurations, oriented in the X and Y directions, within local convex subareas.
  • Figure 11 A show horizontal cross-sectional slices, of a Stanford bunny, and showing a linking bridge toolpath.
  • Figure 1 IB show horizontal cross-sectional slices, of a Stanford bunny, and showing a linking bridge toolpath.
  • Figure 11C is a schematic illustration of an example overlapping and interweaving pattern for a horizontal slice whereby interweave is obtained at the end of 4 th layer.
  • Figure 1 ID is a 3D visualization of an example overlapping and interweave pattern for a horizontal slice showing the interwoven print.
  • Figure 12 show horizontal cross-sectional slices, of a Stanford bunny and double nut structure, and showing an overlapping and interweaving toolpath with boundary layers, where the different paths overlap and interweave.
  • Figure 13 show horizontal cross-sectional slices, of a Stanford bunny and double nut structure, and showing artifacts of a continuous overlapping and interweaving toolpath.
  • Figure 14A show horizontal cross-sectional slices, of a Stanford bunny and double nut structure, and showing ray casting to determine convex areas in the X-direction.
  • Figure 14B show horizontal cross-sectional slices, of a Stanford bunny and double nut structure, and showing ray casting to determine convex areas in the Y-direction.
  • Figure 15 show various horizontal cross-sectional slices, of a Stanford bunny and double nut structure, and showing a modified zig-zag toolpath.
  • Figure 16 show various horizontal cross-sectional slices, of a Stanford bunny and double nut structure, and showing a modified overlapping continuous toolpath.
  • Figure 17A is an example simplified hardware block diagram for an example additive manufacturing (AM) system.
  • AM additive manufacturing
  • Figure 17B is an example simplified hardware block diagram for an example computer terminal.
  • Embodiments described below generally relate to methods and systems for manufacturing of polymer-based parts using additive manufacturing.
  • the disclosed embodiments provide a method and system for enabling additive manufacturing of polymer-based parts using a continuous overlapping toolpath.
  • additive Manufacturing is generally known in the art, and refers to a set of manufacturing techniques which involve depositing layer-by-layer material to create a net shape part. In many cases, the manufacturing or building process is based on a virtual model generally generated using computer assisted design (CAD). Examples of additive manufacturing include three- dimensional (3D) printing and rapid prototyping. "Computer Aided Manufacturing” (CAM) is the use of computer-controlled machinery to automate a manufacturing process.
  • CAD computer assisted design
  • 3D three- dimensional
  • CAM Computer Aided Manufacturing
  • CM Composite Material
  • Polymer Matrix Composite is generally known in the art as a composite material composed of a variety of fibers bound together by a matrix of organic polymers.
  • the load carrying fibers can be formed of Kevlar, Aramid, carbon fiber, glass fiber or any syntactic or naturally occurring fiber, only by way of non-limiting examples.
  • the corresponding matrix of organic polymers can be, for example, polyester resin, epoxy resin, and thermoplastics like polylactide (PLA).
  • Polymers are a class of natural or synthetic substances composed of large molecules, i.e., macromolecules, which are multiples of simpler chemical units, i.e., monomers.
  • Polymer-based material refers herein to polymer and/or polymer composite materials.
  • processor refers to one or more electronic devices that is/are capable of reading and executing instructions stored on a memory to perform operations on data, which may be stored on a memory or provided in a data signal.
  • processor includes a plurality of physically discrete, operatively connected devices despite use of the term in the singular.
  • Non-limiting examples of processors include devices referred to as microprocessors, microcontrollers, central processing units (CPU), and digital signal processors.
  • Memory refers to a non-transitory tangible computer-readable medium for storing information in a format readable by a processor, and/or instructions readable by a processor to implement an algorithm.
  • the term "memory” includes a plurality of physically discrete, operatively connected devices despite use of the term in the singular.
  • Non-limiting types of memory include solid- state, optical, and magnetic computer readable media.
  • Memory may be non-volatile or volatile. Instructions stored by a memory may be based on a plurality of programming languages known in the art, with non-limiting examples including the C, C++, Python TM, MATLAB TM, and Java TM programming languages.
  • carbon fiber composite materials have many advantageous properties
  • manufacturing carbon fiber parts is challenging because of the complexity of manufacturing.
  • carbon fiber parts are manufactured using various techniques, including wet lay-up, prepreg lamination and resin transfer molding.
  • a carbon fiber sheet consists of weaves with different patterns, such as plain weave, twill weave, or satin weaves offering different properties such as stability and flexibility.
  • the parts manufactured using wet lay-up, prepreg lamination or resin transfer use a multistep process with significant lead times.
  • Additive manufacturing involves depositing layer-by-layer material to manufacture a net shape part.
  • the building process is based on a virtual model generally created using computer assisted design. Thanks to this method, it is possible to generate internal features and multidirectional prints. When combined with physical data, one can modify the physical, thermal, and mechanical properties of the part.
  • the advantages of carbon fibers can be combined with the ones of AM, such as 3D printed carbon fiber parts.
  • the carbon fiber parts are produced using a filament containing macroscopic fibers wet into a polymer such as PLA (Polylactic acid), ABS (Acrylonitrile Butadiene Styrene) or PEEK (Polyether Ether Ketone). These parts generally offer better properties than commonly 3D printed parts.
  • embodiments herein generally relate to a method and system for manufacturing of polymer-based parts using additive manufacturing.
  • the disclosed embodiments allow for controlling the toolpath of an additive manufacturing system to enable planar and non-planar continuous overlapping printing of a polymer- based material.
  • Disclosed methods combine continuity overlapping inside a single slicing process customized for additive manufacturing.
  • the method involves determining a parametric continuous path with infill and boundary layers for 3D printing of polymer matrices, or polymer matrix composite.
  • the methods comprise a continuous printing of a part using long carbon fibers with a single continuous toolpath.
  • the continuous path provides overlapping deposition of infill lines to produce an interwoven result.
  • the continuous path does not include an "over-under" pattern of adjacent lines, which is the hallmark of a true woven pattern. Instead, the continuous path provides overlapping lines which approximates a woven pattern, as described further below.
  • the continuous path is non-planar in that each path layer overlaps vertically with a previous path layer.
  • interweave or "interwoven” in the context of additive manufacturing or 3D printing, means planning for material extrusion, or directed energy deposition homogenous polymer, or polymer composite 3D print process in a sequential manner whereby, due to interaction between two (2) or more multiple passes of the material extrusion processes, an interweave between the polymer and/or fibers is created.
  • the disclosed methods allow manufacturing of medium to high volume parts with significant bead thickness and bead height (e.g., 1 to 10 mm of diameter).
  • significant bead thickness and bead height e.g. 1 to 10 mm of diameter.
  • the disclosed methods may ease manufacturing complexity, time and costs of medium to large volume 3D parts while preserving the properties of the materials known for their stiffness, low weight to strength ratio, high temperature tolerance, low thermal expansion and high chemical resistance.
  • Figure 1 shows an example system (100) for additive manufacturing of polymer-based parts, in accordance with embodiments described herein.
  • system (100) generally includes an additive manufacturing (AM) system (102).
  • AM system (102) is coupled to a computer terminal (104), via communication network (106).
  • AM system (102) can also couple to an external server, via network (106) (not shown).
  • AM system (102) is a three-dimensional (3D) printer. More generally, as is known in the art, the AM system (102) is able to deposit layer-by-layer materials to generate geometric structures in three-dimensions (3D).
  • the AM system (102) is used to deposit and manufacture 3D parts using polymer-based materials.
  • the following description focuses on a non-limiting example application where the AM system (102) is used for manufacturing parts using a carbon fiber polymer matrix.
  • the AM system (102) can receive input data for a 3D object.
  • the input data can correspond to a computerized or digital 3D object model.
  • this can include a 3D computer-aided-design (CAD) model of the target part.
  • Figure 2 shows example parts that can be manufactured using the AM system (102). These include a model of a Stanford bunny (200a) and a double nut (200b) structure.
  • the AM system (102) may include a deposition assembly (108) comprising a nozzle head, extruder and the like.
  • the deposition assembly (108) can deposit the layer- by-layer material on a printing platform (110).
  • the deposition assembly (108) is mounted to a support structure (112).
  • the AM system (102) may also include various other components. These may include various driving subsystems (e.g., stepper motors), power sources, control systems, displays, deposit supplies, single or multi-material extruder, or a composite polymer matrix fiber extruder etc.
  • driving subsystems e.g., stepper motors
  • control systems e.g., display, deposit supplies, single or multi-material extruder, or a composite polymer matrix fiber extruder etc.
  • the AM system (102) is a 3- to 8-axis machine.
  • System (100) can also include the computer terminal (104).
  • the computer terminal (104) can provide an interface for user(s) to generate, receive and/or store the input modelling data for the 3D part requiring manufacturing.
  • the input data is then transmitted to the additive manufacturing (AM) system (102) for manufacturing.
  • AM additive manufacturing
  • the computer terminal (104) can generally include a processor (1702b) coupled to a memory (1704b), a display interface (1706b), an input interface (1708b), and a communication interface (1710b).
  • system (100) may not necessarily include the computer terminal (104).
  • the AM system (102) may itself include its own input and display interface for user interaction.
  • system (100) can include one or more servers for storing and transmitting the input 3D data to the AM system (102).
  • Communication network (106) can be an internet, or intranet network.
  • network (106) may be connected to the internet.
  • the connection between network (106) and the internet may be made via a firewall server (not shown).
  • firewall server not shown
  • Some organizations may operate multiple networks (106) or virtual networks (106), which can be internetworked or isolated. These have been omitted for ease of illustration, however it will be understood that the teachings herein can be applied to such systems.
  • Network (106) may be constructed from one or more computer network technologies, such as IEEE 802.3 (Ethernet), IEEE 802.11 and similar technologies.
  • the computer (104) may be connected to the AM system (102) by any commercially available short range communication protocol, such as BluetoothTM or the like. IV. EXAMPLE METHOD(S)
  • the following is a description of example methods for manufacturing of parts from polymer-based materials (e.g., carbon fiber composite materials) using additive manufacturing.
  • the methods enable additive manufacturing using a continuous overlapping toolpath.
  • the methods allow for manufacturing parts with enhanced mechanical, structural and physical properties.
  • Figure 3A shows one embodiment of a process flow for an example method (300a) for additive manufacturing of three-dimensional (3D) parts.
  • the entirety of method (300a) is performed by the additive manufacturing (AM) system (102).
  • AM additive manufacturing
  • input three-dimensional (3D) part model data is accessed.
  • the input data corresponds to the 3D part requiring manufacturing.
  • the input data can include a geometric definition of the 3D object, as well as derived geometric metadata. This can include various wireframes, surfaces or solids that may be represented in any fashion.
  • the input data is a CAD model, such as a Standard Triangle Language (STL) file.
  • STL Standard Triangle Language
  • the input 3D data is stored and accessed on a memory of the additive manufacturing (AM) system (102).
  • the input 3D data is received from an external source by the AM system (102).
  • the external source can be the computer terminal (104), external server(s), or any other computing device or system.
  • the printing parameters can include: (i) layer thickness of deposited material; (ii) bead height; and/or (iii) bead thickness.
  • Other parameters can include various design parameters including the number of boundary layers, percentage of infill, number of paths per layer. These design parameters are explained in greater detail below.
  • the printing parameters can be configurable, user-selectable, or user- adjustable. In other examples, however, at least some of the printing parameters are fixed or predefined.
  • the input 3D part model is sliced (or segmented) into one or more horizontal slices. In this manner, the 3D part model is segmented into "n" horizontal slices (e.g., one or more, or a plurality of horizontal slices).
  • vertical refers to an axis, or plane, extending upwardly and downwardly.
  • a vertical axis or plane extends between a bottom end and top end of the 3D part model.
  • the vertical axis is also referred to herein interchangeably as a “printing axis”, as it corresponds to the axis along which the 3D part is printed by the AM system (102).
  • the "horizontal" axis, or plane is defined in an axis orthogonal to the vertical axis or plane (or printing axis or plane).
  • each horizontal slice will comprise a plurality of path layers.
  • the 3D part models - of the example Stanford bunny (200a) and double nut (200b) - are each sliced (or segmented) into a plurality of horizontal slices (402).
  • the horizontal slicing occurs orthogonal to the printing axis (450), and parallel to the horizontal axis, defined along the reference horizontal Cartesian X-Y-plane.
  • the vertical Z-axis e.g., printing axis (450)
  • Each horizontal slice represents a cross-section of the 3D object, along the X-Y horizontal plane.
  • each horizontal slice represents a separate, and distinct layer deposited by the additive manufacturing (AM) system (102).
  • AM additive manufacturing
  • each horizontal slice is deposited using a continuous overlapping toolpath pattern.
  • the plurality of horizontal layer slices (402), generated at (306a), extend, along the printing axis (450), between a first printable layer and a last printable layer, e.g., in the order in which they are printed by AM system (102).
  • the first printable layer defines the bottom end (404a) of the 3D part model
  • the last printable layer defines the top end (404b) of the 3D part model.
  • the number of horizontal slices is generated based on the known, or pre-defined deposition layer height.
  • the layer height is taken as a multiple y ⁇ l of the actual layer height.
  • the four paths defining the layer are firstly overlapped with an offset y time layer height with y ⁇ 1.
  • the height awareness map is also computed, and the vertical position of each point of the four paths is modified giving the wavy aspect of the final printing path.
  • a slice-specific toolpath pattern (or toolpath configuration) is determined, for each horizontal slice (402).
  • the toolpath configuration for each slice, provides a movement pattern for the deposition assembly (108), of AM system (102) ( Figure 1).
  • the movement pattern is defined in the XY plane (e.g., the plane orthogonal to the printing axis (450)).
  • the toolpath pattern or configuration, for each layer comprises a parametric continuous path defined by a zig-zag and overlapping pattern.
  • Each subsequent layer results in a “quasi-interweave” with the layer immediately deposited below.
  • each toolpath pattern, for each layer comprises four overlapping zig-zag patterns, as disclosed below.
  • the additive manufacturing (AM) system (102) is operated in accordance with a toolpath configuration determined for each of the "n" horizontal slices.
  • the AM system (102) manufactures the 3D object, slice-by-slice (e.g., along printing axis (450)).
  • this involves operating the tool face subsystem (1706a) (FIG. 17A), of the AM system (102), which controls the spatial motion path of the deposition assembly (108) to follow the determined toolpath for each horizontal slice.
  • the AM system (102) is able to deposit all of the constituent slices of the 3D part in a continuous path (i.e., without discontinuities). That is, the continuous deposition is not only performed within each slice - but also, between consecutively and vertically stacked slices.
  • a “continuous path” refers to the ability to operate the AM’s deposition assembly (108), such that the deposition assembly (108) is able to continuously extrude filament material without stopping the extrusion.
  • the deposition assembly (108) does not require stopping the deposition to be relocated to a different spatial position, before continuing extruding filament.
  • Figure 3B shows one embodiment of a process flow for an example method (300b) for determining a layer-specific toolpath configuration.
  • Method (300b) expands on act (308a), of method (300a).
  • at act (302b) for a given horizontal slice - at least an external two- dimensional (2D) boundary envelope of that slice is determined, wherein the 2D boundary envelope is defined in the horizontal plane (e.g., orthogonal to printing axis (450)). If present, at least one internal boundary envelope of the slice is also identified.
  • 2D two- dimensional
  • a "boundary” or “envelope” refers to a set of points organized in a sequenced manner. Each point is linked to its previous and next neighbors by segments forming a line set.
  • the system uses the intersections between a horizontal plane at layer "k", and the part, to compute the 2D boundaries of the part at layer "k”.
  • the system can consider both the external and internal boundaries, and can organize them into a graph so that the offset direction is always known.
  • Figure 5 shows an example 2D layer (500) for the double nut structure (200b).
  • the respective internal boundaries (502) and external boundaries (504) are identified, e.g., based on where the spaces (e.g., voids) around and within the part are located at that horizontal layer.
  • one or more closed printable cross-sectional areas are determined, based on the determined boundary envelopes (also referred to herein as, “printable areas” or “printable cross- sectional areas”).
  • the envelope boundaries - determined for a given horizontal slice - define (e.g., enclose) one or more closed printable areas, corresponding to a non-void area of the 3D part in that horizontal slice.
  • Each printable area (550), within a given horizontal layer, is fully bounded by one or more envelopes, along the horizontal plane.
  • a printable area defines an area of the horizontal slice that requires printing using filament material. For example, this refers to printable area (550) for the double nut structure (FIG. 5), and printable area (550) for the Stanford bunny structure (FIGs. 6 - 7).
  • the computed printable cross-sectional area(s) are also determined (e.g., classified and/or identified) to be either concave or convex, relative to the known pre-defined deposited bead thickness.
  • a printable area (550) is considered “concave” if it is impossible to generate a toolpath for the deposition assembly (108), along a given toolpath printing direction, that covers the entirety of the printable area (550), for a given slice layer, with a continuous linear "zigzag" path with a thickness equal to the bead thickness.
  • a "convex" printable area can be filled with a continuous, uninterrupted zig-zag path with a thickness equal to the bead thickness.
  • a zig-zag path refers to a pattern that includes one or more extending linear line portions, whereby adjacent line portions are connected together by curved connecting portions, as known in the art.
  • a toolpath printing direction refers to a direction, defined along the horizontal slice plane, along which the deposition assembly (108) translates along the linear portions of a zig-zag pattern, in order to deposit material within the printable area (550) (e.g., X-axis and/or Y-axis, or at any angle thereof).
  • the toolpath printing directions may be pre-defined for the AM system, or otherwise, user-selectable.
  • the disclosed embodiments allow for two toolpath printing directions, which are orthogonal to each other in the horizontal plane (e.g., orthogonal to the printing axis (450)), e.g., X-axis and Y-axis directions.
  • Figures 6A and 7A show a single horizontal slice of the Stanford bunny (200a), and further clarifies the difference between “concave” and “convex” printable areas.
  • each horizontal layer can be printed along both the X- and Y- axis directions. Generating zig-zags in both the X-direction and the Y-direction allows forming the slice from an overlapping pattern. That is, the overlapping is generated by operating the nozzle toolpath - of the AM system (102) - in both the X-direction and the Y-direction. As provided previously, generating a slice comprising continuous overlapping patterns enhances the mechanical and structural properties of the 3D part.
  • the printable area (550), defined by envelope (602a), is considered “concave” at act (304b) when the toolpath is moved along the X-axis. This is because it is not possible to fill the entirety of the printable area (550) with a continuous zig-zag path, along the X- axis.
  • printable subarea (604a) it is possible to operate the toolpath in the X-axis, and along a continuous, uninterrupted zig-zag toolpath. This is represented by the arrows (606a).
  • the printable subarea (608a) forms a discontinuity zone, which prevents operating the toolpath in a continuous, uninterrupted linear manner.
  • printable area (550) is therefore considered “concave" in the X-direction, e.g., as it is not possible to generate a continuous path, along the X-axis, that fills-in (e.g., covers) the entirety of the printable area (550).
  • a discontinuity zone (708a) prevents forming a continuous path along the entirety of the printable area (550). Therefore, the printable area (550) is also considered a concave envelope with respect to the Y- direction.
  • the system can determine if one or more discontinuity zones exist.
  • a discontinuity zone refers to a subarea, of the printable area (550), which prevents operating the toolpath, in a given printing direction, along a continuous path along the entirety of the printable area (550).
  • the toolpath cannot operate continuously (e.g., in a continuous zig-zag pattern), along a given printing direction, while maintaining the toolpath within the boundary envelope(s) defining the printable area (550), and without otherwise overlapping (or re-overlapping) over an area (or subarea) that was previously covered by the toolpath.
  • determining whether a printable area (550), is "concave” versus “convex” is a direction-specific determination.
  • a separate determination is made as to whether: (i) the printable area (550) is concave if the toolpath is operated in the first printing direction (e.g., X-direction); and (ii) the printable area (550) is concave if the toolpath is operated in the second printing direction (e.g., Y-direction).
  • the same determination is also made if the toolpath is operated in any other direction (e.g., at a non-right angle to the X or Y axis, in the XY plane).
  • a printable area (550) can be concave in one direction, but convex in another direction. Accordingly, the determination at (306b) can be made for each printing direction used, for a given horizontal layer, as well as for each printable area (550) within the horizontal layer.
  • the system can therefore determine the toolpath printing directions used by the AM system (102). The system may then determine, for each printable area (550) within the horizontal layer, whether that printable area (550) is concave or convex, with respect to each toolpath printing direction.
  • the system determines if a printable area (550) is concave in a given printing direction (e.g., X- and/or Y- direction). If the printable area (550) is determined to be concave in a given printing direction - then at act (310b), at least two local convex printable subareas are determined for that toolpath direction. That is, the concave printable cross-sectional area is segmented into at least two local convex subareas, for that printing direction.
  • a printable area (550) is concave in a given printing direction (e.g., X- and/or Y- direction). If the printable area (550) is determined to be concave in a given printing direction - then at act (310b), at least two local convex printable subareas are determined for that toolpath direction. That is, the concave printable cross-sectional area is segmented into at least two local convex subareas, for that printing direction.
  • the at least two convex subareas are defined such as to remove (e.g., eliminate) any discontinuity zones, in the horizontal layer, for a given printing direction. This facilitates the desired continuous printing path.
  • At least two local convex subareas (602b), (604b) are determined for the X-direction.
  • the convex subareas (602b), (604b) eliminate the discontinuity zone (608a).
  • it is now possible to generate a continuous, uninterrupted zig-zag toolpath pattern within each of the printable subareas (602b), (604b) see e.g., 900ai and 900a2 in Figure 9A). Therefore, these areas are now referenced as "convex" subareas while operating the tool along the X-axis.
  • one or more local convex subareas (702b), (704b) are determined for the Y-direction. Again, the convex subareas (702b), (704b) eliminate the discontinuity zone (708a). Therefore, it is now again possible to generate a continuous, uninterrupted toolpath pattern within each of printable subareas (702b), (704b) (see e.g., 900bi and 900b2 in Figure 9B). Accordingly, each of these area is referenced as "convex" subarea when operating the toolpath in the Y-axis. [00131] Once again, it will be understood that determining local convex subareas - at act (308b) - is also direction-specific, for a given toolpath printing direction.
  • Figure 6B shows direction-specific convex subareas (602b), (604b) for the X-direction.
  • Figure 7B shows direction-specific convex subareas (602b), (604b) for the Y-direction. Therefore, as used herein, "direction-specific convex subareas" are convex printable subareas associated with a particular toolpath printing direction.
  • FIGS 8A and 8B further exemplify acts (308b) and (310b), but for the double nut structure.
  • FIGS 8A and 8B show a cross-sectional envelope (802) for the double nut structure.
  • the printable area (550), defined by envelope (802), is determined to be concave because it is not possible to generate a continuous, uninterrupted zig-zag pattern in either direction. In this example, however, there are multiple discontinuity zones, at least in the X-direction.
  • the concave area (550) is segmented into a plurality of direction-specific convex subareas (804a) - (810a). Within each convex subarea (804a) - (810a), it is possible to generate a continuous zig-zag pattern in the X- direction (see e.g., toolpath pattern lOOOai in Figure 10A).
  • the concave area (550) is again segmented into one or more direction-specific local convex subareas (804b), (806b). Within each convex subarea (804b), (806b) it is possible to generate a continuous zig-zag pattern in the Y- direction (see e.g., toolpath pattern 1000a2 in Figure 10B). [00138] Continuing with reference to Figure 3B, at act (312b), for each direction-specific convex subarea, one or more sets of toolpath pattern configurations are determined.
  • the one or more sets of toolpath pattern configurations include first and second toolpath patterns, which are oriented in that printing direction.
  • the second toolpath pattern is offset from the first toolpath pattern, such that the first toolpath pattern is a “non-offsef ’ pattern, and the second tool path pattern is an “offset” pattern (as explained below).
  • Figure 9A shows the local convex subareas (602b), (604b) generated for the X- direction (e.g., Figure 6B).
  • a first toolpath pattern or configuration is determined in the X-direction.
  • This toolpath pattern is determined for each local convex subarea (602b), (604b), and covers the entire area (based on the determined bead thickness).
  • the zig-zag pattern begins and ends at the layer envelope.
  • a second toolpath configuration is also determined, at act (310b), in the X-direction, for each convex subarea (602b), (604b).
  • the path is determined with an offset equal to the bead thickness.
  • offset means that the path is not directly superimposed on top of another path (e.g., along printing axis (450)), or in other words, the path is positioned between adjacent lines of another path, when viewed vertically.
  • the amount of offset is substantially equal to /i the distance between adjacent lines of the zig-zag path.
  • the first toolpath in (900ai) is referenced as a "non-offset” path, while the second path in (900a2) is referenced as a "with offset” path.
  • generating two toolpath patterns in the X-direction (and subsequently, for the Y-direction) enables generating the desired overlapping pattern.
  • At act (312b) to generate the zig-zag pattern - ray casting in the toolpath printing direction (e.g., X-direction) is applied to obtain intersections with the envelope boundary, of each convex subarea, at equal distances from each other. All the points, for consecutive rays, are then linked together to form a zig-zag toolpath (e.g., linked with curved portions).
  • the toolpath printing direction e.g., X-direction
  • Figure 9B shows the convex subareas (702b), (704b) generated for the Y-direction (e.g., Figure 7B).
  • a first "non-offset" toolpath zig-zag pattern is determined for each convex subarea (702b), (704b) in the Y-direction.
  • a second "with offset” toolpath pattern is determined for each convex subarea (702a), (702b), also for the Y-direction.
  • the four zig-zag paths (900ai), (900a2), (900b i), (900b2) are combined to enable overlapping to generate the overlapped layer for that horizontal slice.
  • Figures 10A to 10B illustrate a similar process for a horizontal slice of the double nut structure (200b).
  • Figure 10A shows a first "non-offset” toolpath determined for the X- direction (lOOOai) within the concave subareas (804a) - (810a). Further, a first "non-offset” toolpath is also determined in the Y-direction (1000a2) for each of the concave subareas (804b) - (806b).
  • Figure 10B shows a second "with offset” toolpath determined for both the X-direction (lOOObi) and the Y- direction (1000b2).
  • Figure 11 A shows a horizontal cross-section of the Stanford bunny (200a). As shown, (900ai) shows the convex subareas (602b), (604b) filled-in with the first "nonoffset" zig-zag toolpath, in the X-direction ( Figure 9A).
  • a linking path (1102) is determined to connect the toolpaths between the convex subareas (602b), (604b). In this manner, a continuous toolpath is now generated in the X-direction between the two convex areas (602b), (604b).
  • the continuous path can: (i) start at boundary point (1150a), (ii) zig-zag through convex area (602b), (iii) continue through linking path (1102a); (iv) zig-zag through convex area (604b); and (v) terminate at end point (1152a).
  • the continuous path can traverse in the reverse direction, such that it starts at point (1152a) and terminates at point (1150a).
  • envelope (900bi) shows the convex subareas (702b), (704b) filled-in (e.g., entirely filled-in) with the first "non-offset" toolpath pattern, in the Y-direction ( Figure 9B).
  • a linking path (1104) is identified to connect the toolpath between the convex subareas (702b), (704b). Accordingly, the system generates a continuous toolpath between the convex subareas (702b), (704b). In turn, a continuous and uninterrupted toolpath in the Y-direction is generated for the entire horizontal slice.
  • a first toolpath direction e.g., X-direction
  • the first toolpath direction e.g., X-direction
  • a second toolpath direction e.g., Y-direction
  • the second toolpath direction e.g., Y- direction
  • each of these direction-specific linked, or continuous toolpath patterns can be combined to generate the overlapped pattern for the horizontal layer.
  • (lOOOai) shows each local convex subarea - in the X-direction - filled-in using the first "non-offset" toolpath configuration.
  • Linking paths (1102b) - (1106b) are identified to connect the multiple toolpaths between each convex subarea (804a) - (810a). Accordingly, a single uninterrupted toolpath is resolved, linking all convex subareas in the X-direction.
  • (lOOObi) shows each sub-convex area - in the Y-direction - filled-in using the first "non-offset" toolpath configuration.
  • a linking path (1108b) is identified to connect the toolpaths between the two convex subareas (804b) - (806b). Accordingly, a single uninterrupted toolpath is resolved, linking all convex subareas in the Y-direction.
  • the linking paths can be determined in any manner.
  • the linking paths are determined by using the end point of the toolpath for one convex subarea, and the closest entry point of the next convex subarea, e.g., an entry point referring to a terminal path point touching or nearest-adjacent the envelope boundary.
  • the next entry point can be at the initial start or end of the toolpath for that convex subarea. If the closest entry point correspond to the initial end of the toolpath in the next subarea, the sequence of points forming the toolpath of the next subarea is then inverted. In this manner, it can be said that each toolpath pattern represents an ordered sequence of points.
  • act (314b) can be performed using any number of convex subareas.
  • any number of linking paths are determined to connect all convex subareas in one continuous path. Accordingly, some convex areas may link at both ends (1150a), (1152a) to separate and adjacent (i.e., neighboring) convex areas.
  • the printable area (550) is not determined to be concave for a given toolpath direction (e.g., X or Y direction), then the printable area (550) is determined to be convex in that direction. Accordingly, in that case, method (300b) can immediately perform act (316b).
  • a given toolpath direction e.g., X or Y direction
  • the method involves simply determining a zig-zag pattern - in that toolpath direction - within that convex area. For example, the entire convex are is filled-in with an X- direction or Y-direction zig-zag toolpath. This is similar to act (312b), but without using local convex subareas. In some examples, similar to act (316b), at least two toolpaths are also determined at (316b) in a given printing direction (e.g., with offset and without offset).
  • act (316b) can still generate at least four continuous toolpath patterns.
  • act (316b) can generate two continuous toolpath patterns in the X-direction (e.g., with and without offset).
  • acts (310b) - (314b) can generate two further continuous toolpaths in the Y-direction (e.g., with and without offset).
  • the opposite scenario is also possible with respect to the X- and Y-directions.
  • the final overlapped toolpath pattern is generated by connecting the multiple direction-specific toolpaths. That is, the toolpaths are overlaid each other in the vertical or Z-direction (e.g., printing axis (450)), and connected to each other. The toolpaths are overlaid such that the envelope boundaries, delineated around each toolpath (and therefore, the printable areas), are aligned and matched along printing axis (450).
  • act (318b) involves vertically stacking (e.g., along printing axis (450)), and connecting the toolpaths in the following order: (i) the first continuous path in the first toolpath direction (e.g., X-direction) without offset (e.g., lOOOai in Figure 10A) is connected to, (ii) the second continuous path in the second toolpath direction (e.g., Y-direction) without offset (1000a2 in Figure 10A) is connected to, (iii) the third continuous path in the first toolpath direction (e.g., X-direction) with an offset equal to the bead height (lOOObi in Figure 10B) is connected to, (iv) the fourth continuous path in the second toolpath direction (e.g., Y-direction) with an offset equal to the bead height (1000b2 in Figure 10B).
  • the first continuous path in the first toolpath direction e.g., X-direction
  • the first path represents the vertically lowermost layer
  • the fourth path represents the vertically upper-most layer within the slice.
  • the result is shown schematically in Figures 11C and 1 ID, where the first and third paths overlap vertically with the second path, while the second and fourth paths overlap vertically with the third path.
  • Each of the four paths thus overlap horizontally with a horizontal offset between the first and third paths and the second and fourth paths respectively, and overlap vertically.
  • the boundary envelope(s) may again be used, as previously explained, and implemented with offsets.
  • the in-fill layer (1202a) comprises the multiple, overlapping toolpaths in either toolpath direction (e.g., X- and Y-directions). These are also referenced herein as "in-fill toolpaths”.
  • the boundary layer (1202b) surrounds the in-fill layer (1202a), and defines the outer envelope of the horizontal slice, and corresponds to the boundary envelopes of the horizontal slice.
  • the boundary layer itself, can comprise multiple "boundary toolpaths" (1204) - (1208).
  • each boundary toolpath can link two of the in-fill toolpaths together (e.g., first path to second path; second path to third path; third path to fourth path, etc.).
  • the boundary toolpaths can connect the starting or terminating points (1150a), (1152a) of overlaid in-fill toolpaths ( Figure 11 A). Accordingly, the in-fill toolpaths are connected together at the boundary.
  • three offset values are chosen to compute four boundary toolpaths.
  • a direction of right or left is implemented (e.g., right or left around the envelope).
  • the first boundary toolpath is used to link the first and second path using the right direction and the third and last path using the left direction.
  • the second boundary toolpath is used to link the second and third paths.
  • the third boundary toolpath starts at the end of the fourth path and goes around the part to form the net shape aspect (see e.g., Figure 10A and 10B).
  • Method (300b) can be re-iterated for each horizontal slice, determined at act (306a) in Figure 3A.
  • the last boundary toolpath of each slice can also be used to join the previous and next slice together.
  • the offset for each boundary layer is preferably implemented in a way that the maximum overlap between layers in the XY plan and in the Z direction is around 50%. In this manner, the toolpath is not just continuous within a slice, but as between multiple slices. Accordingly, the 3D part can be manufactured with a total continuous toolpath.
  • one or more of acts (302a) - (308a) can be performed on computer terminal (104), or otherwise, any other external server.
  • acts (302a) - (308a) can be performed on computer terminal (104), or an external server.
  • the toolpath configuration is determined at act (308a), it can then be transmitted to the additive manufacturing (AM) system (102) to execute act (310a).
  • AM additive manufacturing
  • acts (302a) - (308a) can be performed by any combination of the AM system (102) and the computer terminal (103) (or any other external server).
  • method (300b) can be performed by the computer terminal (104) (or an external server) and/or any combination of the computer terminal (104) (or external server), and the AM system (102).
  • Figures 14A and 14B provide an example technique for resolving local convex subareas, at act (310b) in Figure 3B, for a given toolpath direction (e.g., X-direction or Y-direction).
  • a given toolpath direction e.g., X-direction or Y-direction.
  • Figure 14A shows a technique for determine local convex subareas when operating the toolpath in the X-direction (e.g., zig-zags extending along the X-axis).
  • Figure 14B shows a technique for determining local convex subareas when operating the toolpath in the Y-direction (e.g., zig-zags extending along the Y-axis).
  • the method can involve generating a series of rays that are casted in the toolpath direction, e.g., X-direction ( Figure 14A) and Y-direction ( Figure 14B), and with a spaced distance equal to the pre-defined bead thickness of the AM printer. For each ray, the number of intersections with the envelope boundary, for that horizontal layer, is computed. If the number of intersections is equal to two, then the printable area is considered convex around the casted ray.
  • X-direction Figure 14A
  • Y-direction Figure 14B
  • the system identifies a pair of intersection points (1450) for that ray (FIG. 14A), separated by an area outside the printable area (550). Between each pair of intersection points (1450), an intermediate point (1402) is determined for that ray, where the intermediate point (1402) is equally distally located - along that ray - between the pair of intersection points (1450) (see dotted line along which point (1420) is disposed, between points (1450)). For intermediate points (1402) disposed along a common line orthogonal to the rays, these points are adjoined along a common linking ray (1404), which defines a segmentation line to segment different convex subareas.
  • a zig-zag pattern is used.
  • the circled areas (1302) highlighted in Figures 13 A and 13B, weaker boundaries are observed in between the local convex areas, in the overlapped patterns (1300a) and (1300b) for each of the Stanford bunny and the double nut structure.
  • the zig-zag parameters can be modified such as presented in Figure 15.
  • Figure 15 shows modified zig-zag parameters for local convex subareas for the Stanford bunny in the X-direction (1500a) and Y-direction (1500b). Also shown is the modified zig-zag parameters for the double-nut in the Y-direction (1500c).
  • the toolpaths presented in Figure 15 show a non-linear bounding between two convex subareas.
  • the zig-zag patterns crosses-over between the local convex subareas. This mitigates for weakened zones (1302) ( Figure 13). In turn, this generates a modified overlapping continuous toolpath having improved mechanical properties at the interfaces between the local convex subareas.
  • FIG. 16 shows the modified overlapped toolpath for a layer of the Stanford bunny (1600a), and also including the connecting boundary layers (1600b). Similarly, the modified toolpath is shown for a layer of the double nut (1600c), and also including the connecting boundary layer (1600d).
  • the modified zig-zag configuration can be used for all, or some, of the horizontal slices.
  • a convolution filter was enabled to smooth the curvature of each turn.
  • the number of paths was also be modified to increase the radius of curvature. In other words, instead of having two paths with an offset equal to twice the bead thickness, a path can be added with an offset equal to three (3) times the bead thickness and consequently increase the radius of curvature.
  • curvature while changing direction is also considered using a convolution filter.
  • this can be modified at act (304a) in Figure 3A.
  • a "lower slice awareness" map is generated to avoid collision between the deposition nozzle and the previously deposit matrix.
  • This map may encode the vertical motion of the nozzle according to the average height of material deposited in its closed neighborhood.
  • a height awareness map can be generated. This map aims to minimize the collisions between the nozzle and the material already deposited but it is also to maintain a continuous material flow along the printing.
  • the height awareness map is reinitialized.
  • the height awareness map takes as input a discretized version of the paths located below the current path for which the map is computed and another discretized version of the current path.
  • the nearest neighbors inside the underneath path are selected.
  • the z value of the studied point is then modified to be far enough from any underneath neighbors.
  • the influence of each neighbor is implemented according to the distance between the studied point and the selected neighbor.
  • the described methods are coded using “foundation” python libraries providing elementary objects such as polygons, lines and points and useful linear algebra and geometry functions.
  • sequence of algorithms is coded in Python and uses open-source libraries available under the MIT license.
  • the sequence is implemented in a way that all the printing parameters are fully customizable.
  • the only fixed parameters are the type of infill pattern (zigzag) and the number of axes (3 - axis 3D printing)
  • the computational time for the slicing process with zig-zag infill is in the same order as open-source slicers such as Cura or Slic3r when no support is computed.
  • open-source slicers such as Cura or Slic3r when no support is computed.
  • Figure 17A shows a simplified hardware block diagram of an example additive manufacturing system (102).
  • the system includes a processor (1702a) coupled, via a data bus, to a memory (1704a) and one or more of a tool face (or deposition) subsystem (1706a), communication interface (1708a), display interface (1710a) and an input interface (1712a).
  • a processor (1702a) coupled, via a data bus, to a memory (1704a) and one or more of a tool face (or deposition) subsystem (1706a), communication interface (1708a), display interface (1710a) and an input interface (1712a).
  • communication interface (1708a) may comprise a cellular modem and antenna for wireless transmission of data to the communications network.
  • Display interface (1710a) can be an output interface for displaying data (e.g., an LCD screen).
  • Input interface (1712a) can be any interface for receiving user inputs (e.g., a keyboard, mouse, touchscreen, etc.). In some examples, the display and input interface or one of the same (e.g., in the case of a touchscreen display).
  • AM system (102) As carrying out a function or acting in a particular way imply that processor (1702a) is executing instructions (e.g., a software program) stored in memory (1704a) and possibly transmitting or receiving inputs and outputs via one or more interface.
  • instructions e.g., a software program
  • the tool face (deposition) subsystem (1706a) comprises the deposition assembly (108), as explained above.
  • This subsystem (1706a) is controllable to execute the printing of 3D part components in accordance with the disclosed methods.
  • FIG. 17B shows a simplified hardware block diagram of an example computer terminal (104).
  • the computer terminal (104) includes a processor (1702b) coupled, via a data bus, to a memory (1704b) and one or more of a display interface (1706b), an input interface (1706b) and a communication interface (1710b). These components may have an analogous hardware architecture of the communication interface (1708a), display interface (1710a) and an input interface (1712a).
  • processor (1702b) is executing instructions (e.g., a software program) stored in memory (1704b) and possibly transmitting or receiving inputs and outputs via one or more interface.
  • instructions e.g., a software program
  • system (100) includes external servers, they may have an analogous architecture as the computer terminal (104), although they may not necessarily include an input and display interface.
  • Coupled can have several different meanings depending in the context in which these terms are used.
  • the terms coupled or coupling may be used to indicate that an element or device can electrically, optically, or wirelessly send data to another element or device as well as receive data from another element or device.
  • two or more components are said to be “coupled”, or “connected” where the parts are joined or operate together either directly or indirectly (i.e., through one or more intermediate components), so long as a link occurs.
  • two or more parts are said to be “directly coupled”, or “directly connected”, where the parts are joined or operate together without intervening intermediate components.
  • the example embodiments of the systems and methods described herein may be implemented as a combination of hardware or software.
  • the example embodiments described herein may be implemented, at least in part, by using one or more computer programs, executing on one or more programmable devices comprising at least one processing element, and a data storage element (including volatile memory, non-volatile memory, storage elements, or any combination thereof).
  • These devices may also have at least one input device (e.g. a pushbutton keyboard, mouse, a touchscreen, and the like), and at least one output device (e.g. a display screen, a printer, a wireless radio, and the like) depending on the nature of the device.
  • At least some of these software programs may be stored on a storage media (e.g. a computer readable medium such as, but not limited to, ROM, magnetic disk, optical disc) or a device that is readable by a general or special purpose programmable device.
  • the software program code when read by the programmable device, configures the programmable device to operate in a new, specific and predefined manner in order to perform at least one of the methods described herein.
  • the programs associated with the systems and methods of the embodiments described herein may be capable of being distributed in a computer program product comprising a computer readable medium that bears computer usable instructions for one or more processors.
  • the medium may be provided in various forms, including non-transitory forms such as, but not limited to, one or more diskettes, compact disks, tapes, chips, and magnetic and electronic storage.
  • the computer program product may also be distributed in an over-the-air or wireless manner, using a wireless data connection.
  • the term “software application” or “application” refers to computer-executable instructions, particularly computer-executable instructions stored in a non-transitory medium, such as a non-volatile memory, and executed by a computer processor.
  • the computer processor when executing the instructions, may receive inputs and transmit outputs to any of a variety of input or output devices to which it is coupled.
  • Software applications may include mobile applications or “apps” for use on mobile devices such as smartphones and tablets or other “smart” devices.
  • a software application can be, for example, a monolithic software application, built inhouse by the organization and possibly running on custom hardware; a set of interconnected modular subsystems running on similar or diverse hardware; a software-as-a-service application operated remotely by a third party; third party software running on outsourced infrastructure, etc.
  • a software application also may be less formal, or constructed in ad hoc fashion, such as a programmable spreadsheet document that has been modified to perform computations for the organization’s needs.
  • Software applications may be deployed to and installed on a computing device on which it is to operate.
  • an application may be deployed directly to the computing device, and/or the application may be downloaded from an application marketplace.
  • user of the user device may download the application through an app store such as the Apple App StoreTM or GoogleTM PlayTM.

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  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)

Abstract

L'invention concerne des procédés et des systèmes de fabrication d'une pièce à base de polymère à l'aide d'une fabrication additive par (a) génération d'une pluralité de tranches horizontales d'un modèle de pièce tridimensionnelle (3D) virtuelle ; (b) pour chaque tranche horizontale, détermination d'une configuration de trajectoire d'outil spécifique de tranche pour générer un motif de trajectoire continue d'outil à chevauchement et entrelacement pour cette tranche ; et (c) fabrication de la pièce par actionnement d'un système de fabrication additive selon la configuration de trajectoire d'outil spécifique de tranche pour chaque couche.
PCT/CA2023/051678 2022-12-16 2023-12-15 Procédé et système de fabrication de pièces à base de polymère entrelacé à l'aide d'une fabrication additive Ceased WO2024124355A1 (fr)

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US63/433,336 2022-12-16

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2018127274A1 (fr) * 2017-01-03 2018-07-12 L3F Sweden Ab Procédé d'impression d'un produit 3d et dispositif d'impression 3d
US20180215094A1 (en) * 2017-01-27 2018-08-02 The Government Of The United States Of America, As Represented By The Secretary Of The Navy Method and Apparatus for Volumetric Manufacture of Composite Objects
WO2022066980A2 (fr) * 2020-09-24 2022-03-31 Camegie Mellon University Bain de support transparent pour impression 3d intégrée et système de surveillance en cours de processus

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2018127274A1 (fr) * 2017-01-03 2018-07-12 L3F Sweden Ab Procédé d'impression d'un produit 3d et dispositif d'impression 3d
US20180215094A1 (en) * 2017-01-27 2018-08-02 The Government Of The United States Of America, As Represented By The Secretary Of The Navy Method and Apparatus for Volumetric Manufacture of Composite Objects
WO2022066980A2 (fr) * 2020-09-24 2022-03-31 Camegie Mellon University Bain de support transparent pour impression 3d intégrée et système de surveillance en cours de processus

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