Overhang Structure Management in 3D Printing

A method and device for 3D printing complex shapes without support structures. The method involves dividing the suspended surfaces of the 3D model into subregions on a 2D plane. The subregions are scanned and melted layer by layer using parallel melting lines. The division directions change layer by layer to prevent overlapping. This allows printing suspended surfaces without supports by transitioning smoothly to non-suspended areas. The device implements this method for unsupported 3D printing.

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Additive manufacturing method for complex metal parts that improves material utilization and reduces defects compared to conventional methods. The method involves partitioning the complex part into smaller sub-parts based on its features, and then planning the additive manufacturing trajectories dynamically for each sub-part. This allows optimizing the fill overlap and reducing excess material compared to uniform overlap for the whole part. The partitioned trajectory planning increases material utilization while maintaining overall part accuracy by accounting for the specific structure of each sub-part.

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Producing supported 3D-printed articles with complex geometry using a method that optimizes throughput, material properties, and post-processing speed for high-resolution 3D printing. The method involves determining the concave hull of the 3D-printed article with fine features, finding vertices on the hull that need support during printing, and printing the article and support pillars together using 3D printing. This enables nesting operations, self-intersecting geometries, and controlled resin flow. After printing, the supports can be severed.

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Generating 3D printing files that reduce support material usage and printing time by creating multi-layer supports with steps instead of vertical supports. The method involves calculating suspended areas for each layer of the support structure based on the model geometry. This allows printing the supports at a speed that cools and solidifies the suspended areas before they sink. By using multi-layer supports with steps, the overall support volume is reduced compared to vertical supports, which saves material and printing time.

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Additive manufacturing method and device for 3D printing complex parts with porous structures that avoids warping, enables easier support removal, and reduces powder consumption compared to traditional methods. The method involves separately modeling the solid structure, porous structure, and partial solid structure before filling. The support angles are designed based on a threshold. This allows optimizing supports, parameters, and printing sequence to prevent deformation while making removal easier without damaging the porous areas.

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Additive manufacturing technique for forming complex metal structures without supports using selective laser melting (SLM) that enables direct 3D printing of unsupported overhanging features. The method involves optimized SLM parameters and processing steps for forming high-temperature alloy cross-section mutations without supports. It allows direct 3D printing of complex metal structures with unsupported overhanging sections that cannot be formed using conventional SLM. This enables integrated manufacturing of previously unprintable designs with intricate shapes like internal cavities and channels. The technique involves steps like selective laser melting, heat treatment, and surface finishing. It enables direct 3D printing of high-temperature alloys with unsupported overhanging sections without requiring support structures during printing.

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A method and device for 3D printing with conformal supports that avoid the accuracy issues of traditional ceramic blocks. The method involves spraying an isolation film onto the build platform using a dedicated print head. This film isolates the printed part from the platform during the build process. The film is made from powder like ceramic or refractory metal. The powder particles can be sub-micron to hundreds of microns. The smoothness of the film contact improves the surface finish of the printed part. After printing, the isolated part can be easily removed without disturbing the surrounding build. The conformal support avoids issues like shrinkage, deformation, and accuracy loss compared to ceramic blocks.

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3D printing metal parts without support structures to reduce cost and time compared to traditional methods. The key is designing a transition layer that gradually reduces the angle between the part and the build plate as it approaches overhanging features. This prevents the part from collapsing during printing. The transition layer is part of the printed part and not removable. The angle of the transition layer is adjusted based on the overhang angle to avoid failure.

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Large-scale 3D printing method that enables flexible, high-volume 3D printing of complex, large-scale objects. The method involves tilting the print bed at variable angles during 3D printing to overcome limitations of traditional horizontal printing for large, tall, and slender objects. The slicing angles gradually transition as the print progresses to enable seamless printing. The method involves generating transition planes for different angle slice planes and inputting to the printing device. This allows flexible, large-scale 3D printing of complex objects without warping or support structures.

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Using graphite as a support material for 3D printing complex metal parts to overcome limitations of traditional ceramic supports. Graphite has similar sintering temperatures to metal, allows easy removal after sintering, and prevents distortion during printing. The method involves 3D printing the metal part and graphite support simultaneously, debinding and sintering both, then removing the graphite. This allows printing of overhangs and fragile structures without needing specialized supports. The graphite mixture also improves printability and removability compared to ceramics.

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A process method for 3D printing aluminum alloy thin-walled parts that improves success rate and efficiency by optimizing printing parameters and using support structures. The method involves modeling the part with added thin-walled supports, then printing with tailored parameters for the part interior, boundary, and top, as well as the support structure. This allows customizing settings to mitigate deformation and breaking during printing.

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Additive manufacturing (AM) process using non-continuous deposition to build 3D objects layer by layer with discrete deposits instead of continuous extrusion. The process involves filling a 3D model with hexagonally packed cells and sorting them to sequence discrete deposits in a way that maximizes deposition rate while minimizing residual stress and distortion. This involves arranging deposits to avoid direct contact between adjacent deposits in a layer. The discrete deposits are made using a welding process like GMAW to build the object. The non-continuous deposition allows scalability without interference and reduces costs compared to continuous extrusion processes.

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3D printing method for creating suspended structures without the need for additional support structures. The method involves printing a mesh-like or filament-like support layer inside the printed object. This allows the overhanging parts to hang from the internal support instead of needing external supports. After printing, the excess internal support can be removed using tools like CNC machines, grinders, or scissors.

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Optimizing the printing direction of 3D models to enhance structural strength, improve quality, and reduce distortion during 3D printing. The optimization considers factors like support volume, thermal deformation, staircase effect, and print time to find the best printing direction. It uses a genetic algorithm to solve the multi-objective optimization problem and find the optimal direction that balances all factors. This comprehensive approach addresses shortcomings of existing methods that ignore thermal deformation.

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A method to enable printing 3D objects with complex overhanging geometries without any support structures that need to be manually removed. The method involves adding an erodible support structure that can be printed along with the object and then erodes away after printing. The support structure consists of thin ligament segments anchored to the inner surface of the object and connecting to the overhanging geometry. During printing, the material is printed through the erodible support to create the overhang. After printing, the erodible support can be dissolved or otherwise removed, leaving the unsupported overhang intact.

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Method for 3D printing overhangs without support structures that can easily be removed after printing. The method involves generating pillars below the overhangs that are coupled to the 3D model and placed on the build plate. This prevents warping during printing. Support structures are also generated to support the overhangs during the print process. After printing, the pillars can be easily removed since they are part of the 3D model, whereas the support structures are detachable. This allows cleaner post-processing of the overhang areas compared to traditional support structures.

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Optimized design of lightweight supports for 3D printing that improve stability, accuracy, efficiency, and material usage compared to traditional supports. The design involves splitting the support into an upper contact part and a lower volume part. The upper part directly touches the 3D printed part with a small contact area for easy removal. The lower part contacts the build plate to stabilize the upper part during printing. This allows using less material for the lower volume part compared to traditional supports. The design reduces support material waste, printing time, and part warping/deformation compared to solid or block supports.

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3D printing algorithm for overhanging structures using a multi-axis rotary table that allows printing without supports. The algorithm involves converting the non-parallel layers of an overhanging structure into parallel slices using the rotary table's movement capabilities. This allows printing without supports as the table rotates to make the overhangs parallel. The algorithm also has a filling method for non-parallel slices using the rotary table's motion to convert back to 2D for filling. This enables printing overhangs without supports or waste material.

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3D printing technique to create suspended 3D structures without the need for additional support during printing. The method involves controlling factors like inclination angle, layer thickness, and width-height ratio of extrusion lines to balance the thixotropic fluid properties and prevent collapsing of suspended structures. This allows direct printing of semi-suspended 3D shapes without the need for extra supports that are later removed. The thixotropic fluid used is a water-based polyurethane resin with specific ratios of thickener and curing agent to provide suitable printing properties.

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Printing 3D objects with improved quality, reduced defects, and increased design flexibility compared to conventional 3D printing methods. The technique involves using two energy sources, like lasers, to print overhangs with curved surfaces. One energy source forms the overhang, and the other reshapes it by impinging the overhang, hard material, or both. This prevents warping and deformation during printing. The technique also involves monitoring melt pool dynamics, comparing real-time signals to targets, and adjusting print parameters accordingly. It allows printing complex 3D objects with high accuracy, low surface roughness, and low porosity overhangs.

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