Printing Cost Optimization for 3D Manufacturing

Reducing variation in build time for additive manufacturing (AM) by equalizing the sintered volume on each printed layer. It calculates slice area distributions for the desired and sacrificial parts, then plans a layout where, on each plane, the total slice areas match. This balances the sintering time per layer and improves part quality.

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Optimization system for designing lightweight 3D printed parts using modular building blocks with specific shapes. The system involves creating a digital model of the part using modular units with platonic geometric shapes like cubes, tetrahedrons, etc. The system analyzes the test data of printed parts to optimize the arrangement and selection of the modular units. It also analyzes stresses and removes units from regions where stresses are below a threshold. The system aims to create lightweight, optimized parts by leveraging the modular units and their shapes.

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Combined matrix optical lens for UV 3D printers that improves uniformity and efficiency of UV light exposure for high precision 3D printing. The lens design reduces the number of LED units needed to illuminate the LCD screen by using double-sided optics. It also allows customization of lens size based on application requirements to optimize cost and performance.

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Determining locations for support structures in additive manufacturing build parts. The system examines the geometrical characteristics of each segment of a building part at a candidate position relative to the energy source. It determines support locations based on factors like the angle of incidence of each segment relative to the energy source. This allows precise determination of which segments require support to achieve good quality. Reducing unnecessary support can reduce the total amount of support material used in the build process.

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A modular tool assembly for validating machining processes in a timely and cost-effective manner. The assembly is entirely 3D printed using additive manufacturing. It comprises a 3D-printed tool holder, a 3D-printed cutting tool, and a 3D-printed spindle connector. By 3D printing, the entire tool assembly can be rapidly produced and validated without having to rely on expensive machined components. This enables faster and cheaper machining process validation.

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Optimizing additive manufacturing processes by dynamically adjusting fabrication conditions based on object shape. The method involves dividing the object into small elements, sorting them by position type (e.g., curved, flat, edge), and setting fabrication conditions specific to each type. This allows customization of parameters like laser power, speed, etc., for different regions to improve efficiency and prevent defects like lack of fusion or burning through.

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Reducing waste during 3D printing by recycling resins if only one resin is included in a given layer. After a single material layer is printed and leveled, the leveled-off material can be recirculated back to be re-used during printing of another layer. If more than one resin is included in a layer, the leveled-off material cannot be re-used and is deposited in a waste bin and discarded. This reduces waste compared to traditional leveling where all excess material is discarded.

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Lower-cost, highly customizable, and better-performing 3D printed transtibial prosthetic devices that are patient-specific, adjustable, and robust. It uses a unibody design with a 3D-printed socket, pylon, and ankle-foot complex. The unitary polymer structure provides multi-axial dynamic flex like a human ankle. The device can be customized to the patient using digital scanning and 3D modeling. 3D printing enables the fabrication of complex geometry. The integrated unibody design eliminates assembly and sliding connections for better durability.

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An in-situ material regeneration system and method for additive manufacturing, such as 3D printing, enables recovery, reconditioning, and reuse of used powders and liquids collected during the AM process. The system and method involve extracting portions of the powder/liquid at various stages, such as after deposition, wetting, and binding, into separate containers. This allows targeted regeneration processes for each type of material. The collected powders/liquids are regenerated separately or mixed and then reused in subsequent print jobs. The in-situ regeneration reduces waste and material costs compared to discarding and replacing used powders/liquids.

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3D printable parts with integral threads that can be produced in a single print without supports. The key is using a minimum 45 degree angle for the thread flanks, which allows overhangs that can be printed without support material. This enables printing complex parts like screw threads in one piece without separate assembly, reducing cost and complexity compared to conventional manufacturing.

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Method for fabricating components (e.g., patterns, molds, and/or similar products) via techniques or processes similar to 3D printing manufacturing processes of layering, however, using lower cost fill materials without the use of a 3D printer. It involves a layering process to create parts with hollow interiors. The technique uses a CNC router to cut layers from sheets of various materials like MDF and plastic. These layers are stacked and bonded together to form the part shape. The interior is hollow. The part is then infused with a thermoset resin that hardens to create a solid composite.

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A customizable, durable, and cost-effective shoe last for footwear production. The last has a main body that is 3D printed from a polymer material. It also has a movable body part that can slide to adjust the length. The main body and movable part have guiding structures for smooth movement. The 3D printed construction enables customization and reduces costs compared to CNC machining.

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Method for preparing an additive manufacturing program that reduces support structures in additive manufacturing processes. The method involves dividing the 3D model into layers, calculating overhang angles or lengths for each layer, and subdividing layers with overhang angles or lengths below certain thresholds. This allows reducing support structures while maintaining manufacturing quality.

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A 3D printing system with a multi-material feeding device to improve efficiency and reduce costs when using multiple materials in sequential layers. The system has a main printing chamber with a reservoir for the current material. Below the reservoir are separate recovery tanks for each material, connected by valves. After finishing a layer with a material, open the valve to that recovery tank and let the excess flow in. Then close the valve and switch to the next material. This recycles the unused material instead of mixing it together.

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Optimizing 3D printing speed for complex components without sacrificing quality by selectively using faster fabrication speeds for certain layers. The method involves splitting the component into two parts, one printed at a normal speed and the other at a faster speed. This allows thicker layers to be printed faster while maintaining overall thickness. The optimization is done by finding an orientation that maximizes the number of layers that can be printed faster. The method improves manufacturing time/mass ratio by balancing speed and quality for complex components.

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A compact 3D printer that recycles and reuses waste material from FDM printers to reduce material waste and improve print quality. The printer has an integrated recycling and regeneration mechanism that crushes and pulverizes the waste material using a screw pulverizer. The crushed material is then fed back into the printer's extruder and printed using the same nozzle. The recycling mechanism is connected to the printer via a pipe to allow seamless transfer of the recycled material. This closed-loop recycling system reduces waste and enables reuse of previously printed material for new prints.

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Optimizing support structures for 3D printed parts to minimize distortions during sintering. The method involves predicting distortions, optimizing support structures, and checking compliance. The optimized support structure is saved and transmitted to the AM system for fabrication.

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Printing slices of a 3D component model to reduce the time and resources needed to generate a complete 3D print. The method involves receiving a 3D model of a component, an output structure definition, and segmenting the model into slices. Then, for each slice, the method generates a printing layer that includes an arrangement of one or more slice instances of the slice according to the output structure definition. This allows printing a single layer at a time, rather than printing the entire model in one go, which can significantly reduce the time and resources needed.

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A multi-material 3D printing system that improves material efficiency and reduces costs by efficiently recycling excess material between printing jobs. The system has multiple recovery tanks below the build plate that are connected via valves. After completing a print job with one material, the valve to that tank is opened to let the excess material drain into the recovery tank. This prevents mixing of different materials during recycling. Then the valve is closed and the next material is loaded for the next print job.

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Optimizing the mix of fresh and recycled build material for 3D printing to reduce waste and improve part quality. The mix ratio is dynamically adjusted based on factors like packing density and print height to balance fresh vs recycled material. This allows increasing the amount of recycled material without degrading part properties. It prevents excessive aging of the recycled material by using a variable mix ratio that considers factors like packing density and print height.

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