Optimizing 3D Printing Techniques for Overhang Structures

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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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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3D metal printing method and printer that enables printing overhangs and angled features greater than 45 degrees without support structures. The printer identifies sloped edges in each layer and then uses a maximum step-out distance to form those edges at each section of the perimeter. This prevents overhangs from sagging.

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An orientable nozzle for 3D printing that allows the nozzle orientation to be adjusted to improve part stability and strength. The nozzle has a rotatable output that can be angled in any direction relative to the machine's vertical axis. This allows the nozzle to deposit material in any direction, enabling more complex shapes and larger parts. The nozzle orientation can be programmed and controlled by the CNC system.

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Reducing the amount of support material needed during 3D printing by using a dynamic build platform with one or more individually adjustable support members that can be extended into position to support overhanging features as they are printed. The supports are moved after each layer to only support new overhangs instead of printing a full support structure.

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An additive manufacturing system that uses pellets, particles, and/or granular shavings as the raw material. The system has an extrusion apparatus that heats and extrudes the raw material, a heated conduit that maintains the flowable state of the extrudate, and a print head that deposits the flowable material to form an article. The print head has a nozzle that can be tilted and rotated to print at any angle. The system allows for printing in almost any orientation, including at nozzle orientations of less than 45 degrees with respect to a horizontal plane.

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A method of operating a multi-nozzle extruder to improve the structural integrity of sparsely filled interior regions in 3D objects. The method involves moving the extruder along zig-zag patterns to form support structures in the interior regions. The zig-zag patterns have straight and angled portions that intersect at different angles. By alternating the zig-zag patterns, the support structures are formed with different orientations. This improves the structural integrity of the interior regions without compromising the surface features.

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A method for operating a multi-nozzle extruder in a 3D printer to enable an adequate amount of thermoplastic material for swath formation to be established between the faceplate of the extruder and a portion of the object being formed before the extruder reaches the start position for the formation of a swath. The method involves identifying a swath to be formed that requires the closing of all valves in the extruder and lifting of the extruder for movement of the extruder to a start position for the formation of the swath. The method also involves opening at least one valve in the extruder that is identified by extruder path control data for the formation of the swath and moving the extruder from the transition region start position to the start position for the swath to fill a volume between the faceplate of the extruder and the portion of the object being formed by the 3D printer at the start position for the swath.

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Additive manufacturing apparatus that uses sensors and closed-loop control to precisely heat and cool the top layer of feed material to achieve a desired temperature profile. The apparatus has a sensor system that measures temperature and other properties of the top layer. It also has an energy delivery system that selectively heats and cools the top layer based on the sensor data. The system uses a heat source and an energy source to deliver energy to different regions of the top layer. The heat source preheats the platform, while the energy source fuses the feed material. The system uses closed-loop feedback control to adjust the energy delivery based on the sensor data to achieve the desired temperature profile.

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This method supports the 3D printing of objects with complex geometries, especially large hollow shells with thin walls that contain protrusions or overhangs. It uses targeted internal support structures that connect to the object walls and reinforce critical areas. The supports are formed by attaching additional material segments onto the partially printed object.

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A method of operating a multi-nozzle extruder system to enable object portions and support structures to be formed with a single multi-nozzle extruder without extruding different materials from the extruder. The method involves opening more than one nozzle in the extruder and moving the extruder along a path to form a first group of multiple parallel ribbons of support structure simultaneously with material extruded from the more than one open nozzle.

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Extrusion-based additive manufacturing method for 3D printing objects with non-planar layers. The method involves using two extrusion heads, one to form a tool and the other to form the object. The tool is manufactured by extruding a material and depositing it layer by layer on a build plate. The object is then manufactured by extruding the same material and depositing it layer by layer on the tool. The tool and object are manufactured simultaneously using the same extrusion heads.

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Freeform additive manufacturing of three-dimensional objects without support structures by extruding the material into a matrix that maintains its shape as it's being printed. The matrix materials used are graphene aerogel or gelled ionic liquids that can self-heal as the nozzle moves through them. This allows extruding and depositing the material without it collapsing or spreading. The matrix keeps the printed material in place as it cools and solidifies, allowing complex shapes to be formed without the need for external support structures.

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3D printing method and apparatus that enables the use of build materials with higher viscosity and better mechanical properties compared to conventional Fused Filament Fabrication (FFF) methods. The key innovation is aligning the nozzle and hopper openings on a straight axis so the build material can travel along the axis until it reaches the flowable state. This allows using materials that are not flexible enough for conventional FFF methods.

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Additive manufacturing method that allows 3D printing of objects with overhanging or internal features without support structures. The method involves extruding contours of modeling material to form layers that directly connect to the next layer without any intermediate support. The contours are extruded with a slight tilt to connect to the next layer. This allows for 3D printing of objects with overhanging or internal features without the need for additional support structures.

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