Method and apparatus for optimizing a scanning plan in three-dimensional printing

• US 7,962,237 B2
• Filed: 08/06/2008
• Issued: 06/14/2011
• Est. Priority Date: 08/06/2008
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Objet Geometries
• Inventors: Kritchman, Eliahu M.
• Primary Examiner(s): Decady; Albert
• Assistant Examiner(s): STEVENS, THOMAS H
• Application Number:
  US12/186,544
• Publication Number:
  US 20100033521A1
• Time in Patent Office: 1,042 Days
• Field of Search: 347/5, 347/9, 347/237, 347/8, 700/119, 703/6
• US Class Current: 700/119
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes

Abstract

Embodiments of the present invention may include a method for printing three-dimensional objects, layer by layer utilizing an optimized scheme of predefined passes for each layer based on considerations related to both throughput and quality of printing. Embodiment of the invention may include generating a scanning plan for a layer such that the accumulated length for all the scanning passes in the layer is minimized. The optimization scheme may be performed based on image data parameters, such as sizes, locations, dimensions and shapes of the imaged areas of the layer.

Claims

1. A method for printing three-dimensional objects, layer by layer, the method comprising:

automatically generating a pre-designed scanning plan for printing a layer of a three dimensional object in two or more scanning passes by a relative movement in a scanning direction of a printing head and a printing tray, where the pre-designed scanning plan includes a start position, and each of the scanning passes is assigned a respective length determined based on image data parameters of the layer;

performing, by a computing device, an optimization scheme to determine the start position of the pre-designed scanning plan so as to minimize an accumulated length of all lengths of the scanning passes; and

selectively depositing material from the printing head according to the pre-designed scanning plan to form the layer.

2. A method for printing three-dimensional objects, layer by layer, the method comprising:

generating a pre-designed scanning plan for printing a layer of a three dimensional object in two or more scanning passes by a relative movement in a scanning direction of a printing head and a printing tray; and

selectively depositing material from the printing head, based on the pre-designed scanning plan, such that a first scanning pass forms a first imaged area on the layer and a second scanning pass forms a second imaged area on the layer,

where the second scanning pass partially overlaps the first scanning pass and the first and second imaged areas do not overlap.

3. The method of claim 2, wherein the printing head comprises a plurality of nozzles along a longitudinal axis of the printing head, a distance between nozzles located at both ends of the printing head along the longitudinal axis defines printing head size and selectively depositing comprises:

positioning the printing head in a first position such that the longitudinal axis of the printing head is substantially parallel to an indexing direction, the indexing direction being perpendicular to the scanning direction;

generating a relative movement between the printing head and a fabrication tray along a scanning direction in the first scanning pass, substantially perpendicular to the indexing direction while selectively dispensing material from the printing head to form the first imaged area;

re-positioning the printing head in a second position, the second position being offset along the indexing direction from the first position by a distance that is smaller than a size of the printing head; and

generating a relative movement between the printing head and a fabrication tray along the scanning direction in the second scanning pass, while selectively dispensing from a printing head material to form the second imaged area.

4. The method of claim 3, wherein a first length of the first scanning pass is different than a second length of the second scanning pass.

5. The method of claim 3, wherein a start position in the scanning direction for the first scanning pass is different than the start position in the scanning direction for the second scanning pass.

6. A method for printing three-dimensional objects, layer by layer, the method comprising:

generating a pre-designed scanning plan for printing a layer of a three dimensional object in two or more scanning passes by a relative movement in a scanning direction of a printing head and a printing tray, wherein the layer comprises first and second imaged areas separated from each other by a non-imaged area;

selectively depositing material from the printing head according to the pre-designed scanning plan to form the layer;

for each of a plurality of subsequent layers;

prior to depositing material on the first imaged area, re-positioning, within a first range, a start position of the printing head in an indexing direction, the indexing direction being perpendicular to the scanning direction; and

prior to depositing material on the second imaged area, re-positioning the start position of the printing head in the indexing direction within a second range, wherein the second range is different than the first range.

7. The method of claim 6, wherein re-positioning comprises randomly re-positioning the start position of the printing head within the first range and randomly re-positioning the start position of the printing head within the second range.

8. The method of claim 6, wherein re-positioning comprises re-positioning the start positions of the printing head in of the first and second ranges independently from each other.

9. The method of claim 7, wherein re-positioning the printing head within the first or second range is to compensate for mal-functioning nozzles.

10. An article comprising a computer-storage medium having stored thereon instructions that, when executed by a processing platform, result in:

generating a pre-designed scanning plan for printing a layer of a three dimensional object in two or more scanning passes by a relative movement in a scanning direction of a printing head and a printing tray; and

selectively depositing material from the printing head, based on the pre-designed scanning plan, such that a first scanning pass forms a first imaged area on the layer and a second scanning pass forms a second imaged area on the layer,

where the second scanning pass partially overlaps the first scanning pass and the first and second imaged areas do not overlap.

11. A method for printing a three-dimensional object, layer by layer, the method comprising:

selectively depositing material from a printing head in two or more scanning passes to form a layer of the three-dimensional object, wherein a first group comprised of at least one of the scanning passes forms a first imaged area on the layer and a second group comprised of at least one of the scanning passes forms a second imaged area on the layer such that the second imaged area is separated from the first imaged area by a non-imaged area;

for each of a plurality of subsequent layers;

prior to depositing material on the first imaged area, re-positioning, within a first range, a start position of the printing head in an indexing direction, the indexing direction being perpendicular to a scanning direction; and

prior to depositing material on the second imaged area, re-positioning the start position of the printing head in the indexing direction within a second range, wherein the second range is different than the first range.

12. The method of claim 11, wherein re-positioning comprises randomly re-positioning the start position of the printing head within the first range and randomly re-positioning the start position of the printing head within the second range.

13. The method of claim 11, wherein re-positioning comprises re-positioning the start positions of the printing head within the first and second ranges independently from each other.

14. The method of claim 11, wherein re-positioning the printing head within the first or second range is to compensate for mal-functioning nozzles.