Granted Patent B2

US 10,137,635 · App. 15/159,088 · Granted Nov 27, 2018

Inventor: Gregory Lewis Burton (Mountain View, CA)

Assignee: Palo Alto Research Center Incorporated

B29C64/386B29C64/106B33Y10/00B33Y30/00B33Y70/00G05B19/4099B33Y50/02G05B2219/49026

Abstract

Claims (70)

1. A system for printing path planning for functionally graded material with the aid of a digital computer, comprising:

at least one processor configured to execute code, comprising:

a retrieval module configured to retrieve one or more characteristics of a 3D printer, the printer comprising two or more reservoirs, each of the reservoirs shaped to store a printing material, the printer further comprising a mixing chamber for mixing the materials supplied from two or more of the reservoirs upon receiving material extrusion commands, and at least one printer head for extruding the mixed materials as a material mix;

a representation module configured to obtain a representation of a layer of a functionally graded material object, the layer having a polygonal shape and comprising a plurality of points associated with a composition of the material mix, to be printed by the printer, wherein printing by the printer comprises extruding at every point the material mix of the composition associated with that point;

a rate of change module configured to, for each of the points, compute rates of change in the material composition between the composition associated with that point and the compositions associated with one or more other of the points located in one or more directions from that point, and to compare the determined rates of change to a threshold;

a determination module configured to determine for each of the points whether the printer head can move while printing the layer to one or more of the other points along one or more of the directions based on the characteristics, the rates of the change between that point and the other points, and the material composition at that point and the other point, wherein the printer head is determined to be able to move between that point and one of the other points if the rate of change associated with that point and the other point is below the threshold;

a boundary module configured to define boundaries of a plurality of polygons comprised within the polygonal shape that can be printed by the printer head moving in one or more of the directions based on the determinations;

a path module configured to generate a path for the head to follow to print all of the polygons based on the boundaries; and

a command module configured to generate the material extrusion commands based on the generated path,

wherein the printer prints all of the polygons based on the generated path and the material extrusion commands.

2. A system according to claim 1 , wherein the representation comprises a multidimensional array.

3. A system according to claim 1 , wherein the path comprises one of a zig-zag pattern and a direction-parallel pattern.

4. A system according to claim 1 , further comprising:

a portion module configured to divide the path into a plurality of portions,

wherein one of the commands is generated for each of the portions.

5. A system according to claim 1 , further comprising:

a direction module configured to determine a direction within the polygonal shape in which polygons with a greatest area can be defined, wherein the boundaries are defined in the determined direction before the boundaries of remaining ones of the polygons.

6. A system according to claim 1 , further comprising:

a selection module configured to select one or more criteria for the printing;

an optimization module configured to optimize the selected criteria,

wherein the boundaries are defined based on the defined criteria.

7. A system according to claim 6 , further comprising at least one of:

a minimization module configured to minimize a number of stops and starts of movements of the printer head during the printing;

a number module configured to minimize a number of the directions in which the printer head moves during the printing;

a time module configured to minimize a time required for the printing; and

a rate of change module configured to select smallest of the rates of change of the material composition during the printing.

8. A system according to claim 1 , further comprising:

an array module configured to create an array comprising a plurality of values, each of the values indicating whether the printer head can move from one of the points to another one of the points,

wherein the boundaries are defined based on the array.

9. A system according to claim 1 , wherein the characteristics comprise one or more rates at which the composition of the mixed materials in the mixing chamber can change.

10. A method for printing path planning for functionally graded material with the aid of a digital computer, comprising steps of:

retrieving one or more characteristics of a 3D printer, the printer comprising two or more reservoirs, each of the reservoirs shaped to store a printing material, the printer further comprising a mixing chamber for mixing the materials supplied from two or more of the reservoirs upon receiving material extrusion commands, and at least one printer head for extruding the mixed materials as a material mix;

obtaining a representation of a layer of a functionally graded material object, the layer having a polygonal shape and comprising a plurality of points associated with a composition of the material mix, to be printed by the printer, wherein printing by the printer comprises extruding at every point the material mix of the composition associated with that point;

for each of the points, computing rates of change in the material composition between the composition associated with that point and the compositions associated with one or more other of the points located in one or more directions from that point, and to compare the determined rates of change to a threshold;

determining for each of the points whether the printer head can move while printing the layer to one or more of the other points along one or more of the directions based on the characteristics, the rates of the change between that point and the other points, and the material composition at that point and the other point, wherein the printer head is determined to be able to move between that point and one of the other points if the rate of change associated with that point and the other point is below the threshold;

defining boundaries of a plurality of polygons comprised within the polygonal shape that can be printed by the printer head moving in one or more of the directions based on the determinations;

generating a path for the head to follow to print all of the polygons based on the boundaries; and

generating the material extrusion commands based on the generated path,

wherein the steps are performed by a suitably-programmed computer and wherein the printer prints all of the polygons based on the generated path and the material extrusion commands.

11. A method according to claim 10 , wherein the representation comprises a multidimensional array.

12. A method according to claim 10 , wherein the path comprises one of a zig-zag pattern and a direction-parallel pattern.

13. A method according to claim 10 , further comprising:

dividing the path into a plurality of portions,

wherein one of the commands is generated for each of the portions.

14. A method according to claim 10 , further comprising:

determining a direction within the polygonal shape in which polygons with a greatest area can be defined, wherein the boundaries are defined in the determined direction before the boundaries of remaining ones of the polygons.

15. A method according to claim 10 , further comprising:

selecting one or more criteria for the printing;

optimizing the selected criteria,

wherein the boundaries are defined based on the defined criteria.

16. A method according to claim 15 , further comprising at least one of:

minimizing a number of stops and starts of movements of the printer head during the printing;

minimizing a number of the directions in which the printer head moves during the printing;

minimizing a time required for the printing; and

selecting smallest of the rates of change of the material composition during the printing.

17. A method according to claim 10 , further comprising:

creating an array comprising a plurality of values, each of the values indicating whether the printer head can move from one of the points to another one of the points,

wherein the boundaries are defined based on the array.

18. A method according to claim 10 , wherein the characteristics comprise one or more rates at which the composition of the mixed materials in the mixing chamber can change.

19. A system for array-based printing path planning for functionally graded material with the aid of a digital computer, comprising:

at least one processor configured to execute code, comprising:

a retrieval module configured to retrieve one or more characteristics of a 3D printer, the printer comprising two or more reservoirs, each of the reservoirs shaped to store a printing material, the printer further comprising a mixing chamber for mixing the materials supplied from two or more of the reservoirs upon receiving material extrusion commands, and at least one printer head for extruding the mixed materials as a material mix;

a representation module configured to obtain a representation of a layer of a functionally graded material object, the layer having a polygonal shape and comprising a plurality of points associated with a composition of the material mix, to be printed by the printer, wherein printing by the printer comprises extruding at every point the material mix of the composition associated with that point;

a rate of change module configured to, for each of the points, compute rates of change in the material composition between the composition associated with that point and the compositions associated with one or more other of the points located in one or more directions from that point;

a determination module configured to determine for each of the points whether the printer head can move while printing the layer to one or more of the other points along one or more of the directions based on the characteristics, the rates of the change between that point and the other points, and the material composition at that point and the other point;

an array module configured to create an array comprising a plurality of values, each of the values indicating whether the printer head can move from one of the points to another one of the points;

a boundary module configured to define boundaries of a plurality of polygons comprised within the polygonal shape that can be printed by the printer head moving in one or more of the directions based on the determinations indicated by the values in the array;

a path module configured to generate a path for the head to follow to print all of the polygons based on the boundaries; and

a command module configured to generate the material extrusion commands based on the generated path,

wherein the printer prints all of the polygons based on the generated path and the material extrusion commands.

Assignments (9)

Continuity (1)