Systems and methods for controlling additive manufacturing

Patent metadata

Field	Value
Publication number	US-12409608-B2
Application number	US-202217652220-A
Country	US
Kind code	B2
Filing date	Feb 23, 2022
Priority date	Feb 24, 2021
Publication date	Sep 9, 2025
Grant date	Sep 9, 2025

Abstract

Methods and associated systems and apparatus for determining a tool path for use in additively manufacturing a structure. The methods may include receiving data that at least partially defines an outer boundary for a region of the structure, partitioning the region based on placement of a partitioning line across the region from the outer boundary, and generating the tool path to navigate at least part of the outer boundary and to cross, at least partially, the region based on the placement of the partitioning line.

First claim

What is claimed is:

1. A method of determining a tool path for use in additively manufacturing a structure, the method comprising:
receiving data that at least partially defines an outer boundary for a region of the structure;
partitioning the region into a first partition and a second partition based on placement of a partitioning line across the region from the outer boundary;
generating the tool path to navigate at least part of the outer boundary and to cross, at least partially, the region from the first partition into the second partition based on the placement of the partitioning line; and
controlling an additive manufacturing machine to manufacture the structure based on the tool path; and
generating the tool path to navigate at least part of the outer boundary and to cross through the region includes generating the tool path to cross over itself at an intersection within a first layer of the structure; and
legs of the intersection are laterally shifted relative to a second layer of the structure, such that a thickness of the intersection of the first and second layers is the same as a combined thickness of first and second layers.

2. The method of claim 1 , wherein the placement of the partitioning line is determined based on a desired property for the structure.

3. The method of claim 2 , wherein the desired property includes a load the structure is designed to withstand.

4. The method of claim 3 , further including modeling behavior of the structure under a given condition, and determining the desired property based on the modeling.

5. The method of claim 4 , wherein modeling includes generating a property vector field through the structure.

6. The method of claim 4 , wherein modeling includes performing a finite element analysis of the region.

7. The method of claim 1 , further comprising:
modeling behavior of the structure during use based on the tool path;
adjusting the partitioning line based on the modeling; and
regenerating the tool path based on the adjusted partitioning line.

8. The method of claim 1 , wherein:
the partitioning line is a first partitioning line;
the method further includes partitioning the region based on placement of a second partitioning line extending across the region from the outer boundary to form an intersection lane therebetween; and
the tool path crosses through the region within the intersection lane.

9. The method of claim 1 , wherein generating the tool path includes:
generating a section of the tool path navigating along a part of the outer boundary; and
the method further includes:
when the partitioning line is encountered, diverting the tool path to cross through the region; and
when a further part of the outer boundary is encountered, diverting the tool path to navigate along the further part of the outer boundary.

10. The method of claim 9 , wherein:
the tool path has a current direction of propagation;
diverting the tool path to cross through the region includes diverting in a direction that is one of left or right of the current direction of propagation; and
diverting the tool path to navigate along the further part of the outer boundary includes diverting in a direction that is the other of left or right of the current direction of propagation.

11. The method of claim 1 , further including, prior to partitioning the region, generating a seam that is internal to the region, wherein partitioning the region includes placing the partitioning line to extend from the outer boundary to the seam.

12. The method of claim 11 , wherein the tool path further navigates along the seam.

13. The method of claim 1 , further including generating an outer tool path that circumnavigates of the outer boundary and that does not cross through the region.

14. The method of claim 13 , further including combining the tool path and the outer tool path within a single layer of the structure.

15. The method of claim 13 , further including:
using the tool path alone to fabricate a first layer of the structure; and
using the outer tool path alone to fabricate a second layer of the structure.

16. The method of claim 1 , further including compiling and outputting machine code including instructions for controlling an additive manufacturing machine based on the tool path.

17. A non-transitory computer-readable medium encoded with a computer program that, when executed on a computer processor, is configured to undertake steps of:
receiving data that at least partially defines an outer boundary for a region of the structure;
partitioning the region into a first partition and a second partition based on placement of a partitioning line across the region from the outer boundary;
generating the tool path to navigate at least part of the outer boundary and to cross, at least partially, the region from the first partition into the second partition based on the placement of the partitioning line; and
controlling an additive manufacturing machine to manufacture the structure based on the tool path; and
generating the tool path to navigate at least part of the outer boundary and to cross through the region includes generating the tool path to cross over itself at an intersection within a first layer of the structure; and
legs of the intersection are laterally shifted relative to a second layer of the structure, such that a thickness of the intersection of the first and second layers is the same as a combined thickness of first and second layers.

18. An additive manufacture system, comprising:
a moveable support;
a print head connected to the moveable support and configured to discharge a material; and
a computer processor including computer program code that, when executed on the computer processor, is configured to undertake steps of:
receiving data that at least partially defines an outer boundary for a region of the structure;
partitioning the region into a first partition and a second partition based on placement of a partitioning line across the region from the outer boundary;
generating the tool path to navigate at least part of the outer boundary and to cross, at least partially, the region from the first partition into the second partition based on the placement of the partitioning line; and
controlling an additive manufacturing machine to manufacture the structure based on the tool path; and

generating the tool path to navigate at least part of the outer boundary and to cross through the region includes generating the tool path to cross over itself at an intersection within a first layer of the structure; and
legs of the intersection are laterally shifted relative to a second layer of the structure, such that a thickness of the intersection of the first and second layers is the same as a combined thickness of first and second layers.

Assignees

• Continuous Composites Inc

Inventors

• Negugogor Mikel
• Lalonde Logan
• Morris Rachael Kathleen

Classifications

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B29C64/209

  Heads; Nozzles · CPC title

• G06F30/17

  Mechanical parametric or variational design · CPC title

• G06F2113/10

  Additive manufacturing, e.g. three-dimensional [3D] printing · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title