Advances in Cost Reduction for 3D Printing Techniques

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

3D printing process for producing multiple components at once to speed up production. The process involves creating a single CAD file that includes all the components to be produced, arranging them in a way that allows them to be printed in layers on top of each other or next to each other. The CAD file is then used to print all the components simultaneously using a 3D printer. This allows multiple components to be produced in a single printing operation, reducing production time.

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.

Generating support structures for 3D printed objects that can be easily removed after printing. The support structures are generated from the 3D model of the object and the toolpaths for printing. The support structures are designed to cleanly separate from the object after printing. The support structures can be continuous single filament walls that are easy to remove.

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.

Simplifying complex 3D mesh structures generated by generative design to improve manufacturability. The method involves analyzing the mesh to identify candidate regions that can be simplified, then replacing those regions with simpler shapes suitable for traditional fabrication. The remaining complex regions are fabricated using additive techniques. This hybrid approach minimizes the reliance on additive manufacturing while still allowing for 3D structures to be generated based on complex designs.