Key information

Title
METHOD, DEVICE FOR DEVELOPING NON-PLANAR TOOLPATHS TO SOLVE RESTRICTIONS IN ADDITIVE MANUFACTURING
Application number
20241021
Case type
National
Status
15.09.2025 Patent meddelt (B1)
Filed
11.10.2024
Effective date
11.10.2024
Publicly available
15.09.2025
Next annual fee due
31.10.2027
Applicant
BROKKR 3D AS (NO)
Owner
BROKKR 3D AS (NO)
Inventor
Alf Petter Mossevig (NO) et al.
Agent
ACAPO ONSAGERS AS (NO)
Granted
15.09.2025
Patent number
349082
Expiry date
11.10.2044

Abstract and drawing

Disclaimer: This text has been machine-scanned and may contain errors – please refer to "Publications" for legally binding content.
The present invention relates to a method and system for generating non-planar toolpaths in 3D printing, specifically for fused deposition modeling (FDM). The method involves creating a toolpath from a 3D model and dynamically adjusting the toolhead height to create nonplanar toolpaths. The extrusion rate is calculated at each point along the toolpath based on factors including the dynamically changing height, spacing between adjacent segments, and the overhang angle of the surface. The method ensures consistent wall thickness, improved surface finish, and enhanced structural integrity by recalculating extrusion rates and modifying toolpath spacing for sloping and vertical surfaces. The system includes a controller, a dynamic toolhead positioning system, an extrusion rate calculator, and a segment identification module for calculating the normal distance between adjacent toolpath segments. The invention addresses issues of wall thickness inconsistency, weak structural integrity, and overhang limitations in conventional 3D printing.

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 02.09.2026 12-01 Saksbehandling 20241021(349082) UT PT Varsel om betaling av første årsavgift (3317) (PT20241021) ACAPO ONSAGERS AS
 22.09.2025 10-01 Saksbehandling 20241021(349082) UT PT Registreringsbrev nasjonal patent (15) (PT20241021)
16.06.2025 09-01 Saksbehandling 20241021 UT Intention to grant ACAPO ONSAGERS AS
 21.05.2025 08-05 Saksbehandling 20241021 INN P29737NO00 Response to office action ACAPO ONSAGERS AS
 21.05.2025 08-04 Saksbehandling 20241021 INN P29737NO00 Norwegian claims ACAPO ONSAGERS AS
 21.05.2025 08-03 Saksbehandling 20241021 INN P29737NO00 Amended description and claims ACAPO ONSAGERS AS
 21.05.2025 08-02 Saksbehandling 20241021 INN P29737NO00 Amended description and claims, marked-up ACAPO ONSAGERS AS
 21.05.2025 08-01 Saksbehandling 20241021 INN Korrespondanse (Hovedbrev inn) ACAPO ONSAGERS AS
 19.05.2025 07-01 Saksbehandling 20241021 UT Substantive examination ACAPO ONSAGERS AS
 15.05.2025 06-04 Saksbehandling 20241021 INN P29737NO00 Reply 1st OA 15 May 2025 ACAPO ONSAGERS AS
 15.05.2025 06-03 Saksbehandling 20241021 INN P29737NO00 Claim amended markup ACAPO ONSAGERS AS
 15.05.2025 06-02 Saksbehandling 20241021 INN P29737NO00 Claim amended CC ACAPO ONSAGERS AS
 15.05.2025 06-01 Saksbehandling 20241021 INN Korrespondanse (Hovedbrev inn) ACAPO ONSAGERS AS
 09.05.2025 05-02 Saksbehandling 20241021 UT PT report 02:04:11
09.05.2025 05-01 Saksbehandling 20241021 UT Substantive Examination ACAPO ONSAGERS AS
 20.12.2024 04-02 Saksbehandling 20241021 INN BROKKR 3D AS ACAPO ONSAGERS AS
 20.12.2024 04-01 Saksbehandling 20241021 INN Korrespondanse (Hovedbrev inn) ACAPO ONSAGERS AS
 11.10.2024 03-01 Saksbehandling 20241021 UT Formal Examination 1 ACAPO ONSAGERS AS
 11.10.2024 02-01 Saksbehandling 20241021 UT Infobrev til oppfinner ACAPO ONSAGERS AS
 11.10.2024 01-03 Saksbehandling 20241021 INN P29737NO00 Figures ACAPO ONSAGERS AS
 11.10.2024 01-02 Saksbehandling 20241021 INN P29737NO00 Description claims abstract ACAPO ONSAGERS AS
 11.10.2024 01-01 Saksbehandling 20241021 INN Søknadsskjema Patent ACAPO ONSAGERS AS
 11-02 Saksbehandling 20241021 INN Korrespondanse (Hovedbrev inn) ACAPO ONSAGERS AS

Description, claims and drawings

Disclaimer: This text has been machine-scanned and may contain errors – please refer to "Publications" for legally binding content. Description
Technical fieldThe present application pertains to the field of Additive Manufacturing (AM), specifically focusing on Fused Deposition Modeling (FDM) processes and its derivatives. It addresses common issues related to consistent wall thickness, surface finish quality, and overhangs in 3D-printed objects, particularly when using deposition through a nozzle followed by curing through drying, cooling, or other methods.BackgroundAdditive Manufacturing, commonly known as 3D printing, faces several challenges that limit the quality and functionality of the final products. The most significant problems include:1. Inconsistent Wall Thickness: Traditional 3D printing software, known as slicers, divides an object into multiple 2D slices stacked on top of each other. This method leads to inconsistent wall thickness, especially on sloped surfaces, as the predefined layer width, layer height, and perimeter count do not adapt to changes in geometry. This is particularly problematic for applications requiring precise wall thickness, such as transparent objects or "spiral vase" mode prints.2. Monotonous and Weak End Products: The horizontal layering approach of traditional 3D printing results in a monotonous surface finish and weaker structural integrity in certain directions. Products printed using this method often lack aesthetic appeal and exhibit significant strength disparities between the layers.3. Steep Overhangs: Overhangs, where new layers are deposited partially outside the previous layer, present another challenge. The ability of a 3D printer to handle overhangs is limited by the layer height, and reducing layer height globally to accommodate steep overhangs can negatively affect transparency and significantly increase print time. This issue becomes even more pronounced when using wider line thickness and bigger layer heights. Problem 1 relates to the fact that all common slicers (software to establish a toolpath for the 3D-printer) divides the object into several 2-dimensional slices, and stack these on top of each other. The layer width (lw), layer height (lh), and perimeter count (pc) is predefined, meaning that for a sloping surface the wall thickness is lower than that of a vertical wall. The wall thickness can be increased at sloping surfaces using additional perimeters (layers next to each other), but this will only come in integral increments and will not work where a specific number of perimeters are required, e.g. transparent objects and printing in “spiral vase ” -mode. This is illustrated in fig 1 A and B.Problem 2 is similar to 1, where the slicers generate a toolpath by dividing the object into 2-dimensional slices to simplify the toolpath generation. The surface finish of such products is monotonous, with horizontal layers stacked on top of each other, giving a dull and boring appearance. The strength of FDM-based 3D-print is also much higher along the printed lines, while significantly weaker perpendicular to the layers. With layers going only in 2-dimensions, the final end-product is significantly weaker in 1 direction than the 2 other directions.There are some initiatives to use the layers more creatively and one of the most popular publications on the subject is Advanced 3D printing with Grasshopper by Diego García Cuevas and Gianluca Pugliese where they use Grasshopper to create the toolpath directly from the curves defined in Grasshopper. While applicable for a wide range of applications, the method presented there only exacerbates the problem mentioned in bullet point 1, as they do not recalculate the extrusion rate with variable layer heights. It neither solves the problem for any arbitrary geometry, as the toolpath and product design are intrinsically linked, and one needs to design the product from toolpaths from the ground up to use this method.An overhang is defined as a section of a 3D-print where the new perimeter is placed partially outside the previous perimeter as the print goes up, as can be seen in figure 1B. There is only a certain amount of overhang a 3D-printer is capable of, before the surface begins to deform. The overhang angle is dependent on the layer height, and to a certain degree the layer width. Lower layer heights decrease the overhang distance, leading to higher achievable overhang angles.Most slicers achieve better overhang capability by reducing the layer height globally, to the minimum layer height required for steepest overhang angle.However, decreasing the layer height has two problems: (A) For transparent products, the transparency is reduced at lower layer heights, and (B), the print time is significantly increased. A reduction of the layer height by a factor of 2, almost doubles the print time for a given object. This is further illustrated in figure 2 A and B.Current solutions, such as reducing layer height or using creative slicing methods like those described in "Advanced 3D Printing with Grasshopper," only partially address these issues. These methods often exacerbate problems by not recalculating extrusion rates for variable layer heights or by linking the toolpath too closely with the product design. When using planar 3D printing, the extrusion rate calculation is straightforward because the line width and layer height are preset and therefore known at all times. However, using non-planar 3D printing results in constantly changing layer heights. There is no predefined layer height to use for the extrusion calculation. To obtain the correct extrusion rate, the specific layer height has to be calculated at every point on the toolpath to account for the variable layer height.Exemplary background art includes US2024336011A1 that describes a computer system for dynamically controlling a three-dimensional printer that when receiving an indication to cause a three-dimensional printer to print a non-planar surface, calculate multiple different bead sizes for creating the non-planar surface using components of the three-dimensional printer. It also describes generating the multiple different bead sizes at locations within a printing area.Therefore, there is a need for a solution solving the above-mentioned problems. SummaryIn view of the above, an object according to embodiments of the present application is to overcome or at least mitigate drawbacks of the prior art.In particular, the present application discloses a method for generating one or more non-planar coherent toolpaths for extrusion in 3D printing using a fused deposition modeling (FDM) system, which includes generating the one or more non-planar coherent toolpaths containing adjacent toolpath segments, by defining a movement of a toolhead for extruding material, including the steps of adjusting the height of the toolhead dynamically during extrusion to create the one or more non-planar toolpath, identifying the neighboring toolpath segments surrounding a current toolpath segment of the one or more non-planar toolpath using a spatial search algorithm, and using the normal distance between adjacent toolpath segments to determine the material deposition distance, calculating an extrusion rate at each point on the current toolpath based on the dynamically changing toolhead position and a spacing between adjacent toolpath segments, to achieve consistent wall thickness across all slopes and surfaces..The present application also discloses a system corresponding to the abovementioned method.Brief description of the drawingsFigure 1A and 1B: Illustrate the problems with conventional slicers, such as inconsistent wall thickness and weak structural integrity due to horizontal layers. Figure 2 A and 2B: Show the challenges associated with steep overhangs and the limitations of current solutions.Figure 3: Depicts the method of identifying adjacent toolpath segments using a mathematical cylinder.Figure 4: Illustrates the spiralized gcode approach for identifying underlying segments.Figure 5: Demonstrates the calculation of extrusion values using the vector between toolpath segments.Figure 6: Demonstrates the difference between normal slicing and slicing using the new extrusion values and an angled toolheadDetailed descriptionAccording to embodiments of the present application as disclosed herein, the abovementioned disadvantages of solutions according to prior art are eliminated or at least mitigated.In conventional FDM processes, a 3D model is sliced into equally spaced 2D layers. Each slice is then divided into a series of paths that dictate the toolhead's movement to deposit material. The amount of material extruded is calculated using the layer height and width, which works well for vertical surfaces but fails for sloping surfaces, leading to inconsistent wall thickness.Non-planar 3D printing refers to the concept where the z-axis is continuously adjusted during the printing process, allowing the toolpath to move in three dimensions rather than two. The simplest form of this technique is seen in the "Vase Mode" in Prusa Slicer and "Spiralize Outer Contour" in Cura, where the z-value increases continuously.In one embodiment of the present application, software tools like Blender or Fusion 360 are used to import and modify the gcode generated by a slicer. The toolpath is snapped back to the surface of the 3D model and sculpted to maintain consistent wall thickness across different geometries. The spacing between adjacent toolpath lines is adjusted based on the angle of the print surface, with closer spacing on overhangs and wider spacing on vertical sections.For each line segment in the toolpath, the normal distance from the current segment to the segment onto which the material is to be deposited onto is calculated, rather than relying on a fixed layer height. Several methods can be used to identify the relevant segments, such as creating a mathematical cylinder around the segment and finding neighbouring segments or using a spiralized gcode approach.In the following, different embodiments of the present patent application are discussed, referring to the figures.A method and a system is provided to create a non-planar toolpath for arbitrary geometries. It can produce toolpaths for high-performance 3D-printed products with the layer lines used for improved aesthetic appearance. It can produce consistent wall thickness even with sloping geometries and non-planar toolpaths.Now going back to a general process of FDM and other deposition-based 3D-printing methods (paste extrusion, pellet printing, Fused Filament Fabrication (FFF)/FDM) are discussed to put embodiments according to the present application into context.The general process is to take a 3D-model and slice it into equally spaced 2D-layers. This process is known as “slicing” and the computer program that performs this process is known as a “slicer”. Each slice is then divided into a series of paths where the toolhead will move to fill out the slice with extruded material. This path is known as the toolpath. The toolpath is usually transferred to the printer in a file -format called gcode.A toolpath consists of points in space and the printer moves between these points. While moving between these points, the printer also needs to extrude a certain amount of material and this is coded as the E-value (Extruder-value) in the gcode. Calculating the E-value is as simple as taking the height of the slice, which is the distance to the previous layer, the width of the line one wants to extrude, and multiply these two factors with the length of the segment to give the volume which needs to be extrude.This gives the correct amount of material for vertical surfaces, but for sloping surfaces the wall thickness will vary, as the wall-thickness of the object perpendicular to the surface will vary depending on the overhang angle (see figure 1A and figure 1B).The toolpath itself can be created in multiple different ways, one can write it by hand, a slicer as described above can be used, or alternatively design tools like Rhino or Blender to output the toolpath directly from the 3D-modelling software. Common for all of these approaches is that one knows the distance to the previous layer while slicing, so calculating the extrusion value is simple. “Non-planar 3D-printing” refers to the concept where, instead of moving the z-axis in fixed steps upwards and printing one slice at a time, one continually changes the z-value during extrusion moves to make toolpaths that move in 3 dimensions rather than 2. The simplest version of “Non-planar 3D-printing” is the “ Vase Mode” in Prusa Slicer and “Spiralize Outer Contour” in Cura. In these modes, the z -value is continually increasing while the printer moves in x and y. Another example is the Advanced 3D printing with Grasshopper by Diego García Cuevas and Gianluca Pugliese where they use Grasshopper to create the toolpath directly from the curves defined in Grasshopper.According to one embodiment of the present application, this is done by taking a model built in Blender or Fusion 360, sliced it in Prusa Slicer using Vase Mode, and then import the gcode as line segments into Blender as a curve using a custom Python script. The custom python script reads the printer positions output into gcode and constructs a line object in blender from these printer positions. Once the toolpath is imported into Blender the toolpath is snapped back to the surface of the original 3D-model and sculpt the toolpath by dragging the toolpath with “proportional editing” enabled in Blender. The toolpath is sculpted such that the toolpath has the greatest spacing in the Z-direction on the vertical sections of the model, while keeping a low spacing in overhangs and sloping surfaces. The shape of the model is retained while sculpting the toolpath by snapping it to the surface of the original model.The end result is a toolpath with a much more aesthetic appeal and interesting optical properties that uses a low layer height, and better overhang capabilities, where the angle of the print surface is the highest and a high layer height on vertical sections. The overhang capabilities are improved by having a low spacing between adjacent toolpath lines where the angle of the print surface is the highest, and high spacing on vertical sections. Testing shows that it's achievable to vary the layer height by 350% from the lowest to the highest used layer heights.In toolpath generation according to prior art, calculating the E-values of a toolpath segment is relatively straightforward as described above. However, when the toolpaths start to move in 3 dimensions, the correct amount of extruded material is much harder to calculate. All known implementations of Non-planar 3D-printing, like vase mode or the above mentioned grasshopper-book are using an “theoretical” fixed layer height for calculating the extruded material. This method leads to uneven wall thickness and non-uniform surface finish, as in the sections where the toolpaths are packed close, the extruded plastic gets squished resulting in a higher wall thickness, and in the sections with high spacing the plastic gets stretched, resulting in a lower wall thickness. The size of the problem is dependent on the 3 following factors:1) The overhang angles on the printed object2) The slope in the z-axis of the line segment3) The difference between the highest and lowest spacing between two adjacent line segmentsAs long as all 3 of these factors are low, the method of using a “theoretical” fixed layer height for calculating the extruded material does not impose significant artifacts. But as long as one or more of these factors are present that way of calculating the extruded material imposes artifacts, and if two or more factors are present at the same time, the artifacts will render the method unusable.According to embodiments of the present application, calculating the extruded material solves both the problem introduced earlier with varying wall thickness on sloping surfaces, and a way of eliminating the artifacts introduced by non-planar 3D-Printing.The general concept of the embodiments of the present application is that for each line segment in the toolpath find the toolpath onto which the material will be deposited on is found, the distance normal to the segment between these parts of the toolpath is calculated, instead of using a “theoretical” fixed layer height.To find the toolpath onto which the material will be deposited on, several methods can be used.As illustrated in figure 3, a first one is to create a mathematical cylinder around the segment for which the E-value is calculated (segment0). Then all other segments are checked, whether they are entering or exiting the circular end-walls of the cylinder. If they do, it is an adjacent segment and will be marked as a “neighbour segment”, and then loop through all neighbour segments to find the closest. The toolpath to which the deposition distance will be calculated, is the part of the found segment that starts and ends at the short edges of the cylinder.As illustrated in figure 4, a second method according to embodiments of the present application, is for the special use-case of a spiralized g-code. One can then use the fact that the toolpath is a winding spiral that will pass the same point multiple times at increasing z-values. Taking the dot product of the start of the segment in question (segment0) with the start of the previous segment in the g-code (segment-1) one will get a negative number. By continuing backwards on the path, taking the dot product between the start vectors of segment0 and segment-X (where X is an increasing number), at some point the result will become positive, which means being on the point of the spiral directly opposite of segment0. By continuing backwards on the g-code at some point the result turns negative again, which means that being directly below the segment in question, and segmentZ is found. For products with more complex geometries, for example double walls, this check might be True at several locations even though it is not the correct segment. For complex geometries this method can be expanded to every single-walled geometry by doing an additional check to see if the relative distance between segment0 and the found segmentZ is within an acceptable range.As further illustrated in figure 5, once the underlying segment is identified, we can find the vectors between these segments, and calculating the E-value is just a simple arithmetic operation of taking the average of the distance between segment0 and the identified segment (the length of the vector) at the ends of segment0. The distance should be taken normal to the segment0-vector to give the correct extrusion value. Another improvement upon existing solutions is the use of these distance vectors to calculate the optimal nozzle angle. For 5- and 6-axis 3D-printers, we use these vectors directly to continually adjust the angle of the extruder throughout the 3D-print. This ensures that the deposited material is always output normal to the nozzle tip. For normal, planar 3D-printing this can be used to improve the layer adhesion and enable even steeper overhangs, as illustrated in Figure 6.For non-planar 3D-printing aligning the toolhead to the distance vector ensures that the nozzle is always following the slope of the toolpath which is very crucial in application where you have a high degree of non-linearity, as without it, the nozzle itself would crash with the deposited material.The advantages of the embodiments according to the present application compared to prior art are as follows:1. Consistent Wall Thickness: It achieves consistent wall thickness on sloping surfaces and non-planar toolpaths by dynamically recalculating extrusion rates.2. Enhanced Surface Finish: Non-planar toolpaths can be used creatively to produce aesthetically pleasing surfaces.3. Improved Structural Integrity: By adjusting the toolpath and extrusion dynamically, the invention enhances the strength of the printed object, particularly in challenging geometries.
Claims
CLAIMS1. A method for generating one or more non-planar coherent toolpaths for extrusion in 3D printing using a fused deposition modeling (FDM) system, comprising:generating the one or more non-planar coherent toolpaths containing adjacent toolpath segments, by defining a movement of a toolhead for extruding material, including the steps of:o adjusting the height of the toolhead dynamically during extrusion to create the one or more non-planar toolpath;o identifying neighboring toolpath segments surrounding a current toolpath segment of the one or more non-planar toolpath using a spatial search algorithm, and using the normal distance between adjacent toolpath segments to determine a material deposition distance;o calculating an extrusion rate at each point on the current toolpath based on the dynamically changing toolhead position and a spacing between adjacent toolpath segments, to achieve consistent wall thickness across all slopes and surfaces.2. The method of claim 1, wherein defining a movement of a toolhead for extruding material, further includes the step of:o modifying the spacing between adjacent toolpath segments to achieve a coherent surface.3. The method of claim 1 to 2, wherein the spatial search algorithm for identifying neighboring toolpath segments further comprises creating a mathematical cylinder around the current segment to find other segments passing through the ends of that cylinder.4. The method of claim 1 or 3, wherein the extrusion rate is recalculated based on a vector between the current toolpath segment and the identified neighboring segment to optimize material flow for varying geometries.5. The method of any of claims 1 to 4, further comprising adjusting the current toolpath to reduce spacing between adjacent segments on sloping surfaces and increase spacing on vertical surfaces.6. The method of any of claims 1 to 5, wherein the current toolhead is oriented dynamically based on the vector between adjacent toolpath segments to optimize the extrusion angle for improved overhang capabilities.7. The method of any of claims 1 to 6, wherein the extrusion rate is adjusted to vary layer height by up to 350% depending on the geometry of the printed surface.8. The method of any of claims 1 to 7, wherein the overhang angle is dynamically adjusted by calculating a minimum distance between the current toolhead and adjacent segments based on the angle of the print surface.9. A 3D printing system for generating one or more non-planar coherent toolpaths for extrusion in a fused deposition modeling (FDM) system, comprising:○ a toolhead configured to extrude material along one or more non-planar toolpaths;○ a dynamic toolhead positioning system configured to adjust the height of the toolhead during extrusion to generate the one or more non-planar toolpaths;○ a neighboring segment identification module configured to identify adjacent toolpath segments surrounding a current toolpath segment of the one or more non-planar toolpath using a spatial search algorithm;○ a material deposition calculator configured to calculate the normal distance between adjacent toolpath segments to determine a material deposition distance;○ an extrusion rate calculator configured to calculate an extrusion rate at each point along the toolpath based on the dynamically changing toolhead position and a spacing between adjacent toolpath segments to achieve consistent wall thickness across all surfaces.10. The system of claim 9, further comprising a toolpath modification module configured to adjust the spacing between adjacent toolpath segments to achieve a coherent surface.11. The system of claim 9 to 10, wherein the neighboring segment identification module is configured to create a mathematical cylinder around the current toolpath segment and identify other toolpath segments passing through the ends of the cylinder.12. The system of claim 9 or 11, wherein the extrusion rate calculator is configured to recalculate the extrusion rate based on a vector between the current toolpath segment and the identified neighboring segment to optimize material flow for varying geometries.13. The system of any of claims 9 to 12, further comprising a toolpath adjustment module configured to reduce the spacing between adjacent toolpath segments on sloping surfaces and increase the spacing on vertical surfaces.14. The system of any of claims 9 to 13, wherein the dynamic toolhead positioning system is configured to dynamically orient the toolhead based on the vector between adjacent toolpath segments to optimize the extrusion angle for improved overhang capabilities.15. The system of any of claims 9 to 14, wherein the extrusion rate calculator is configured to adjust the layer height by up to 350% depending on the geometry of the printed surface.16. The system of any of claims 9 to 15, further comprising an overhang control module configured to dynamically adjust the overhang angle by calculating the minimum distance between the toolhead and adjacent segments based on the angle of the print surface.PATENTKRAV1. Fremgangsmåte for å generere én eller flere ikke-planare koherente verktøybaner for ekstrusjon i 3D skriving ved å anvende et smeltedeponeringmodelleringssystem (FDM), omfattende:generere den én eller flere ikke-planare koherente verktøybaner innbefattende tilstøtende verktøybanesegmenter, ved å definere en bevegelse av et verktøyhode for materialekstrusjon, inkluderende trinnene å:o justere høyden av verktøyhodet dynamisk under ekstrusjon for å danne den én eller flere ikke-planare verktøybaner;o identifisere tilgrensende verktøybanesegmenter som omgir et aktuelt verktøybanesegment for den én eller flere ikke-planare verktøybaner ved å anvende en romlig søkealgoritme, og anvende normaldistansen mellom tilstøtende verktøybanesegmenter for å bestemme en materialdeponeringsdistanse;o beregne en ekstrusjonsrate ved hvert punkt på den aktuelle verktøybanen basert på den dynamisk endrende verktøyhodeposisjonen og en avstand mellom tilstøtende verktøybanesegmenter, for å oppnå konsistent veggtykkelse over alle skråninger og overflater.2. Fremgangsmåten ifølge krav 1, der å definere en bevegelse av et verktøyhode for materialekstrusjon videre inkluderer trinnet å:o modifisere avstanden mellom tilstøtende verktøybanesegmenter for å oppnå en koherent overflate.3. Fremgangsmåten ifølge krav 1 til 2, der den romlige søkealgoritmen for å identifisere tilgrensende verktøybanesegmenter videre omfatter å danne en matematisk sylinder rundt det aktuelle segmentet for å finne andre segmenter som passerer gjennom endene av den sylinderen.4. Fremgangsmåten ifølge krav 1 eller 3, der ekstrusjonsraten omberegnes basert på en vektor mellom det aktuelle verktøybanesegmentet og det identifiserte tilgrensende segmentet for å optimalisere materialstrømning for varierende geometrier.5. Fremgangsmåten ifølge hvilket som helst av kravene 1 til 4, videre omfattende justering av den aktuelle verktøybanen for å redusere avstand mellom tilstøtende segmenter på skrånende overflater og øke avstand på vertikale overflater .6. Fremgangsmåten ifølge hvilket som helst av kravene 1 til 5, der det aktuelle verktøyhodet orienteres dynamisk basert på vektoren mellom tilstøtende verktøybanesegmenter for å optimalisere ekstrusjonsvinkelen for forbedret overhengegenskaper.7. Fremgangsmåten ifølge hvilket som helst av kravene 1 til 6, der ekstrusjonsraten justeres for å variere laghøyden med opp til 350% avhengig av geometrien til skriveoverflaten.8. Fremgangsmåten ifølge hvilket som helst av kravene 1 til 7, der overhengvinkelen dynamisk justeres ved å beregne en minimumsavstand mellom det aktuelle verktøyhodet og tilstøtende segmenter basert på vinkelen av skriveoverflaten.9. 3D skrivingsystem for å generere én eller flere ikke-planare koherente verktøybaner for ekstrusjon i et smeltedeponering-modelleringssystem (FDM), omfattende:○ et verktøyhode konfigurert for ekstrusjon av et materiale langs én eller flere ikke-planare verktøybaner;○ et dynamisk verktøyhodeposisjoneringssystem konfigurert til å justere høyden av verktøyhodet under ekstrusjon for å danne den én eller flere ikke-planare verktøybaner;○ en tilgrensende segment identifiseringsmodul konfigurert til å identifisere tilstøtende verktøybanesegmenter som omgir et aktuelt verktøybanesegment for den én eller flere ikke-planare verktøybaner ved å anvende en romlig søkealgoritme;○ en materialedeponeringskalkulator konfigurert til å beregne normalavstanden mellom tilstøtende verktøybanesegmenter for å bestemme en materialdeponeringsavstand;○ en ekstrusjonsratekalkulator konfigurert til å beregne en ekstrusjonsrate ved hvert punkt langs verktøybanen basert på den dynamisk endrende verktøyhodeposisjonen og en avstand mellom tilstøtende verktøybanesegmenter, for å oppnå konsistent veggtykkelse over alle overflater.10. Systemet ifølge krav 9, videre omfattende en verktøybanemodifiseringsmodul konfigurert til å justere avstanden mellom tilstøtende segmenter for å oppnå en koherent overflate.11. Systemet ifølge krav 9 eller 10, der den tilgrensende segment identifiseringsmodulen er konfigurert til å danne en matematisk sylinder rundt det aktuelle verktøybanesegmentet og identifisere andre verktøybanesegmenter som passerer gjennom endene av den sylinderen.12. Systemet ifølge krav 9 eller 11, der ekstrusjonsratekalkulator er konfigurert til å omberegne ekstrusjonsraten basert på en vektor mellom det aktuelle verktøybanesegmentet og det identifiserte tilgrensende segmentet for å optimalisere materialstrømning for varierende geometrier.13. Systemet ifølge hvilket som helst av kravene 9 til 12, videre omfattende en verktøybanejusteringsmodul konfigurert til å redusere avstanden mellom tilstøtende segmenter på skrånende overflater og øke avstanden på vertikale overflater.14. Systemet ifølge hvilket som helst av kravene 9 til 13, der det dynamiske verktøyhodeposisjoneringssystemet er konfigurert til å dynamisk orientere verktøyhodet basert på vektoren mellom tilstøtende verktøybanesegmenter for å optimalisere ekstrusjonsvinkelen for forbedret overhengegenskaper.15. Systemet ifølge hvilket som helst av kravene 9 til 14, der ekstrusjonsratekalkulatoren er konfigurert til å justere laghøyden med opp til 350% avhengig av geometrien til skriveoverflaten.16. Systemet ifølge hvilket som helst av kravene 9 til 15, videre omfattende en overhengkontrollmodul konfigurert til å dynamisk justere overhengvinkelen ved å beregne minimumsavstanden mellom verktøyhodet og tilstøtende segmenter basert på vinkelen av skriveoverflaten.
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Patent classes

IPC classesB29C 64/118B29C 64/321B29C 64/343B29C 64/386B29C 64/393B33Y 50/02CPC classesB29C 64/118B29C 64/321B29C 64/343B29C 64/386B29C 64/393B33Y 50/02

Citations

US 2024/0336011 A1 (A1)US 2024/0191181 A1 (A1)US 2016/0263832 A1 (A1)US 2019/0255771 A1 (A1)

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Owners
BROKKR 3D AS
c/o Alf Petter Mossevig, Lofthusveien 13B 0587 OSLO NO (OSLO Municipality, Oslo county)Org. number: 933040712Inventors
Alf Petter Mossevig
Lofthusveien 13 B 0587 OSLO NO (OSLO Municipality, Oslo county)
Mads Ratcke Thomsen
Linjeveien 13 B 1084 OSLO NO (OSLO Municipality, Oslo county)

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ACAPO ONSAGERS AS
ACAPO ONSAGERS AS

Org. number: 932214636

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Edvard Griegs vei 1 5059 BERGEN NO (BERGEN Municipality, Vestland county)
Org. number: 932214636
Reference: P29737NO00

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