Seam concealment for three-dimensional models

• US 9,724,866 B2
• Filed: 12/07/2012
• Issued: 08/08/2017
• Est. Priority Date: 09/23/2009
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Holzwarth, Donald J., Hopkins, Paul E.
• Primary Examiner(s): Daniels, Matthew
• Assistant Examiner(s): Shafi, Leith S
• Application Number:
  US13/707,884
• Publication Number:
  US 20130095303A1
• Time in Patent Office: 1,705 Days
• Field of Search: 4281951, 264 39, 264241, 264299, 264308, 425500, 425516, 425110, 425113, 425130
• CPC Class Codes: B29C 2948/92076 Position, e.g. linear or angular
• CPC Class Codes: B29C 2948/92409 Die; Nozzle zone
• CPC Class Codes: B29C 2948/92428 Calibration, after-treatment, or cooling zone
• CPC Class Codes: B29C 2948/92571 Position, e.g. linear or angular
• CPC Class Codes: B29C 48/09 Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
• CPC Class Codes: B29C 48/21 the layers being joined at their surfaces
• CPC Class Codes: B29C 48/92 Measuring, controlling or regulating
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/171 specially adapted for manufacturing multiple 3D objects
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29K 2025/00 Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
• CPC Class Codes: B29K 2055/02 ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
• CPC Class Codes: B29K 2069/00 Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/00 Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2079/085 Thermoplastic polyimides, e.g. polyesterimides, PEI, i.e. polyetherimides, or polyamideimides; Derivatives thereof
• CPC Class Codes: B29K 2081/06 PSU, i.e. polysulfones; PES, i.e. polyethersulfones or derivatives thereof
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 50/00 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 50/02 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: G05B 19/4099 : Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: Y10T 428/24777 : Edge feature
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]

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.

Claims

1. An extrusion-based digital manufacturing system for building a three-dimensional part, the system comprising:

a computer programmed to;

generate a first tool path for a sliced layers of a digital representation of a three-dimensional model;

adjust the first tool path to a second tool path that is configured to substantially conceal a seam at a perimeter of the corresponding layer of the three-dimensional part; and

generate instructions corresponding to the second tool path;

a platen;

an extrusion head configured to move in a build plane; and

a controller configured to direct the extrusion head to deposit a material to build the three-dimensional model in a layer-by-layer manner in a build plane tool path in the build plane corresponding to the second tool path based on the instructions, wherein the build plane tool path comprises;

an outgoing segment;

a contour segment having a first end extending from the outgoing segment, and a second end; and

an incoming segment extending from the second end of the contour segment, wherein the incoming segment overlaps a portion of the outgoing segment to define an interior region that is enclosed by the build plane tool path, and wherein the outgoing segment and the incoming segment are each partially located within the enclosed interior region.

2. The extrusion-based digital manufacturing system of claim 1, and further comprising a heatable environment in which the three-dimensional model is built in the layer-by-layer manner.

3. The extrusion-based digital manufacturing system of claim 2, wherein the heatable environment comprises an enclosed build chamber.

4. The extrusion-based digital manufacturing system of claim 1, wherein the computer is configured to transmit the instructions to the controller.

5. The extrusion-based digital manufacturing system of claim 1, wherein the outgoing segment, the contour segment, and the incoming segment are each generated based on a predicted road width for the deposited material.

6. The extrusion-based digital manufacturing system of claim 5, wherein the predicted road width ranges from about 250 micrometers to about 1,020 micrometers.

7. An extrusion-based digital manufacturing system for building a three-dimensional part, the system comprising:

a computer programmed to;

generate a first tool path for a sliced layers of a digital representation of a three-dimensional model;

adjust the first tool path to a second tool path that is configured to substantially conceal a seam at a perimeter of the corresponding layer of the three-dimensional part; and

generate instructions corresponding to the second tool path;

a surface configured to support the three-dimensional part;

an extrusion head configured to move in a build plane; and

a controller configured to direct the extrusion head to deposit a material to build the three-dimensional model in a layer-by-layer manner in a build plane tool path in the build plane corresponding to the second tool path based on the instructions, wherein the build plane tool path comprises;

a segment comprising a perimeter of the build plane tool path in a layer, the segment further comprising a first end portion and a second end portion wherein the first end portion and second end portion overlap within an interior region defined by the segment comprising the perimeter of the build plane tool path in the layer.

8. The extrusion-based digital manufacturing system of claim 7 and wherein the surface and the extrusion head move relative to each other in a direction substantially perpendicular to the build plane such that the controller can direct the extrusion head to deposit successive layers to form the three-dimensional model.

9. The extrusion-based digital manufacturing system of claim 7, and further comprising a heatable environment in which the three-dimensional model is built in the layer-by-layer manner.

10. The extrusion-based digital manufacturing system of claim 9, wherein the heatable environment comprises an enclosed build chamber.

11. The extrusion-based digital manufacturing system of claim 7, and further comprising a computer configured to transmit the instructions to the controller.

12. The extrusion-based digital manufacturing system of claim 7, wherein a segment comprising a perimeter having the first and second end segments is generated based on a predicted road width for the deposited material.

13. The extrusion-based digital manufacturing system of claim 12, wherein the predicted road width ranges from about 250 micrometers to about 1,020 micrometers.