Seam concealment for three-dimensional models
First Claim
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1. A method for printing a layer of a three-dimensional part with an extrusion-based digital manufacturing system having an extrusion head, the method comprising:
- depositing a material from the extrusion head at an increasing volumetric flow rate along a first segment of a contour tool path to produce the first segment;
depositing the material from the extrusion head while moving the extrusion head along a perimeter segment of the contour tool path, which extends from the first segment, to produce a perimeter road portion; and
depositing the material from the extrusion head at a decreasing volumetric flow rate while moving the extrusion head along a second segment of the contour tool path which extends from the perimeter segment such that at least a portion of the second segment steps-over a portion of the first segment and thereby forms a seam comprising a step-over portion;
wherein the first segment and the second segment each have a reduced volume of the deposited material at the seam compared to the contour tool path segment;
wherein the step-over portion of the first portion and the second portion has substantially a same height and width as a height and width of the contour road portion; and
wherein the seam reduces surface porosity of the three-dimensional part.
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Abstract
A three-dimensional model built with an extrusion-based digital manufacturing system, and having a perimeter based on a contour tool path that defines an interior region of a layer of the three-dimensional model, where at least one of a start point and a stop point of the contour tool path is located within the interior region of the layer.
49 Citations
17 Claims
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1. A method for printing a layer of a three-dimensional part with an extrusion-based digital manufacturing system having an extrusion head, the method comprising:
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depositing a material from the extrusion head at an increasing volumetric flow rate along a first segment of a contour tool path to produce the first segment; depositing the material from the extrusion head while moving the extrusion head along a perimeter segment of the contour tool path, which extends from the first segment, to produce a perimeter road portion; and depositing the material from the extrusion head at a decreasing volumetric flow rate while moving the extrusion head along a second segment of the contour tool path which extends from the perimeter segment such that at least a portion of the second segment steps-over a portion of the first segment and thereby forms a seam comprising a step-over portion; wherein the first segment and the second segment each have a reduced volume of the deposited material at the seam compared to the contour tool path segment; wherein the step-over portion of the first portion and the second portion has substantially a same height and width as a height and width of the contour road portion; and wherein the seam reduces surface porosity of the three-dimensional part. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method for printing a layer of a three-dimensional part with an extrusion-based digital manufacturing system having an extrusion head, the method comprising:
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depositing a material from the extrusion head at an increasing volumetric flow rate along a first segment of a contour tool path to produce an outgoing road portion; depositing the material from the extrusion head while moving the extrusion head along a perimeter segment of the contour tool path, which extends from the first segment, to produce a perimeter road portion having a height and width; and depositing the material from the extrusion head at a decreasing volumetric flow rate while moving the extrusion head along a second segment of the contour tool path which extends from the perimeter segment such that at least a portion of the second segment contacts a portion of the first segment and thereby forms a seam comprising a step-over portion; wherein the first segment and the second segment each have a reduced volume of the deposited material at the seam compared to the contour tool path segment such that the seam has substantially a same height and width as the height and width of the perimeter road portion; and wherein the seam reduces surface porosity of the three-dimensional part. - View Dependent Claims (9, 10, 11, 12)
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13. A method for printing a layer of a three-dimensional part with an extrusion-based digital manufacturing system having an extrusion head, the method comprising:
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depositing a material from the extrusion head at an increasing volumetric flow rate along a first segment of a contour tool path such that the first portion has an increasing height from a first height to a second height; depositing the material from the extrusion head while moving the extrusion head along a perimeter segment of the contour tool path, which extends from the first segment, to produce a perimeter road portion having a height proximate the second height; and depositing the material from the extrusion head along a second segment at a decreasing volumetric flow rate such that the second segment has a height that decreases from the second height to the first height, wherein the first and second segments abut each other and form a seam substantially having the second height; and wherein the seam reduces surface porosity of the three-dimensional part. - View Dependent Claims (14, 15, 16, 17)
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Specification