Printing Cost Optimization for 3D Manufacturing

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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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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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 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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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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Reducing the large quantity of 3D data that typically has to be sent to a 3D printer during the printing process, thereby making 3D printing systems and processes more efficient, faster and less costly.

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A system to optimize material usage in 3D printing by monitoring and analyzing print conditions along with residual material levels. The system collects data on print layers, material usage, and patterns. It then analyzes and compares the print and residual material data using weighted formulas and morphological range assignments. This detailed analysis allows guiding measures to be made that rationally increase material utilization and optimize resource usage.

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A method for 3D printing multi-material models that reduces material waste and cost by reusing remaining material. The method involves smoothly transitioning between printing the auxiliary structure with leftover material and the main structure with the correct material. When a color change occurs during printing, instead of discarding the leftover material, the print head moves to the auxiliary structure to finish printing it using the remaining material. This allows reusing the leftover material instead of wasting it. After the auxiliary structure is completed, the print head returns to the main structure to continue printing using the correct material.

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A system to manage 3D printers that considers the unique features of 3D printing versus 2D printing. The system collects job execution history from 3D printers and simulates the impact of factors like layer thickness, filling density, and infill pattern on factors like print time, material usage, and power consumption. By simulating these changes, the system can calculate and display the savings in resources and productivity that would result from adjusting 3D printer settings. This provides a 3D printer-specific way to report and compare cost, resource, and productivity savings from different printing conditions.

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Optimizing 3D printing processes by intelligently managing powder supply for better efficiency and yield. The method involves forecasting powder supply levels based on current usage and predicting future demands. It then adjusts print parameters, schedules, and powder ratios to balance primary new powder with recycled powder. This helps avoid shortages, optimize recycling, and minimize waste. The system tracks powder levels, alerts when primary sources run low, and recommends actions to maintain sufficient powder for ongoing and future prints.

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3D printing support generation that reduces the amount of support material needed to print 3D objects. The method involves dynamically identifying overhanging surfaces in a 3D model and generating support posts that connect the overhanging surfaces to the print bed. This allows the 3D printer to print the object without support material where possible, reducing the amount of material needed and improving print quality.

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Non-cement based cementitious material for 3D printing that has faster setting times and lower costs compared to cement-based materials. The material is made by combining fly ash, slag powder, silica fume, lithium silicate, polyacrylic acid water reducer, and graphene oxide in specific proportions. The graphene oxide improves toughness and strength, while the polyacrylic acid water reducer enhances workability. This allows 3D printing of complex structures without collapsing. The material's components are weighed separately, mixed, and dispersed to create a non-cement based cementitious material suitable for 3D printing.

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Efficiently generating job files for 3D printing by dividing the preparation process into two steps. The first step is creating a reusable intermediate file called the Part-to-Build file. This file contains the necessary manufacturing data extracted from the CAD model, like orientation, support, feature, and slicing. The second step is generating the actual job file using the Part-to-Build file, exposure strategy, and nesting. This allows avoiding repeated calculation and input for each job.

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Reducing material consumption in 3D printing while preventing deformation of the printed object. The method involves calculating the required support regions based on the cross-sectional data of the object layers and determining the appropriate support type based on the load applied from above. This allows for optimized support placement that minimizes material usage while maintaining structural integrity.

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