CN117836120A - System and method for 3D printing of non-planar surfaces - Google Patents

Abstract

A computer system for dynamically controlling a three-dimensional printer may include one or more processors and one or more computer-readable media having stored thereon executable instructions that, when executed by the one or more processors, configure the computer system to perform various actions. The computer system may receive an indication to cause the three-dimensional printer to print a non-planar surface. Additionally, the computer system may calculate a plurality of different bead sizes to create the non-planar surface using components of the three-dimensional printer. The computer system may also create commands to generate the plurality of different bead sizes at locations within the print zone.

Description

System and method for 3D printing of non-planar surfaces

Cross Reference to Related Applications

The present application claims priority and benefit from U.S. provisional application serial No. 63/269,547 entitled "system and METHOD FOR 3D PRINTING NON-PLANAR SURFACEs" (SYSTEM AND METHOD FOR 3D PRINTING a NON-PLANAR SURFACE), filed 3 month 18 of 2022, and also claims priority and benefit from U.S. provisional application serial No. 63/230,577 entitled "system and METHOD FOR 3D PRINTING NON-PLANAR SURFACEs" (SYSTEM AND METHOD FOR 3D PRINTING a NON-PLANAR SURFACE), filed 8 month 6 of 2021. All of the above applications are incorporated by reference in their entirety.

Technical Field

The present invention relates to computer control of a three-dimensional printing method using co-reactive materials.

Background

Three-dimensional (3D) printing (also known as additive manufacturing) has experienced a technical explosion in the past few years. This growing interest is related to the ability of 3D printing to easily fabricate a wide variety of objects from common Computer Aided Design (CAD) files. In 3D printing, the composition is placed in successive layers of material to build up the structure. These layers may be produced from, for example, liquid, powder, paper or sheet materials.

In some conventional configurations, 3D printing systems utilize thermoplastic materials. The 3D printing system extrudes the thermoplastic material through the heated nozzle onto the platen. Using instructions derived from the CAD file, the system moves the nozzle relative to the platform, thereby continuously building layers of thermoplastic material to form the 3D object. After extrusion from the nozzle, the thermoplastic material cools. The resulting 3D object is thus made of thermoplastic material layers which are extruded in heated form and layered on top of each other.

There are many ways in which 3D printing can be improved. These improvements may include faster printing, higher resolution printing, more durable end products, and many other desirable results.

Disclosure of Invention

A computer system for dynamically controlling a three-dimensional printer may include one or more processors and one or more computer-readable media having stored thereon executable instructions that, when executed by the one or more processors, configure the computer system to perform various actions. The computer system may receive an indication to cause the thermoset three-dimensional printer to print a non-planar surface. Additionally, the computer system may calculate a plurality of different bead sizes to create the non-planar surface using a thermoset component. The computer system may also create commands to generate the plurality of different bead size ratios at locations within the print zone.

Additionally, a computer-implemented method for dynamically controlling a three-dimensional printer may be executed on one or more processors. The computer-implemented method may include receiving an indication to cause a thermoset three-dimensional printer to print a non-planar surface. Additionally, the computer-implemented method may include calculating a plurality of different bead sizes to create the non-planar surface using a thermoset component. The computer-implemented method may further include creating a command to generate the plurality of different bead sizes at specific locations within the print zone.

Further, a computer-readable medium may include one or more physical computer-readable storage media having stored thereon executable instructions that, when executed by a processor, cause a computer system to perform a method for dynamically controlling a three-dimensional printer. The method performed may include receiving an indication to cause the thermoset three-dimensional printer to print a non-planar surface. Additionally, the performed method may include calculating a plurality of different bead sizes to create the non-planar surface using a thermoset component. The executed method may further include creating a command to generate the plurality of different bead sizes at specific locations within the print zone.

Additional features and advantages of exemplary embodiments of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the exemplary embodiments. The features and advantages of such embodiments may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of such exemplary embodiments as set forth hereinafter.

Drawings

In order to describe the manner in which the above-recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings.

Fig. 1 illustrates a system for thermoset 3D printing.

FIG. 2 shows a schematic diagram of a computer system for thermoset 3D printing.

Figure 3 shows side views of different bead sizes.

Fig. 4 shows different bead sizes along the tool path.

Fig. 5 shows different bead sizes along multiple tool paths.

Fig. 6A shows a side view of different bead sizes along a non-planar surface.

Fig. 6B shows another side view of different bead sizes along a non-planar surface.

Fig. 6C shows another side view of different bead sizes along a non-planar surface.

Fig. 7 shows a flowchart of steps for dynamically controlling a thermoset three-dimensional (3D) printer.

Fig. 8 illustrates an example of the dimensions of a desired non-planar surface.

Fig. 9 illustrates an example tool path along a ramp (i.e., tapered surface).

Fig. 10 illustrates the different extrusion rates of the ramp down and up run shown in fig. 9 to compensate for the hysteresis of the extruded material.

Fig. 11 shows an example of adjacent error diffusion and forward error diffusion.

Fig. 12A and 12B show examples of embodiments of error diffusion in different layers.

Detailed Description

The present invention extends to systems, methods, and apparatus for dynamically controlling a three-dimensional (3D) printer. Systems, methods, and apparatus operate by depositing material during creation of a target object. In some embodiments, the material deposited by the three-dimensional printer is a co-reactive material and the 3D printer is a thermoset printer. As used herein, a "target object" may refer to a portion of a physical object or a complete physical object additively manufactured by the systems, methods, and/or devices described herein. Additionally, as used herein, the co-reactive material comprises a thermoset material. Note that while some of the embodiments described herein relate to a thermal 3D printer configured to extrude co-reactive materials, the principles described herein are applicable to any other 3D printer as well.

Additive manufacturing using co-reactive components has several advantages over alternative additive manufacturing methods. As used herein, "additive manufacturing" refers to using computer-aided design (e.g., by a user-generated file or 3D object scanner) to cause an additive manufacturing apparatus to deposit material layer-by-layer in a precise geometry. Additive manufacturing using co-reactive components may result in a more robust component because the materials forming the successive layers may co-react to form covalent bonds between the layers. Moreover, because the components have low viscosity when mixed, higher filler contents can be used. Higher filler content may be used to alter mechanical and/or electrical properties of the material such as, but not limited to, density, thermal expansion, thermal conductivity, chemical resistance, glass transition temperature (Tg), elongation at break, surface energy, electrical conductivity, and the object of construction. The co-reactive components may extend the chemical constituents used in the additive manufactured part to provide improved properties such as solvent resistance and heat resistance.

In addition, the ability to control the use of co-reactive components within an additive manufacturing environment using a computer system provides several advantages. For example, the computer system can dynamically control and adjust the flow rates, pump speeds, gantry speeds, and/or tool paths of the co-reactive components in a manner that produces desired physical properties of the resulting material. This adjustment and control provides unique advantages within additive manufacturing.

For the purposes of the following detailed description, it is to be understood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. Furthermore, all numbers expressing, for example, quantities of ingredients used in the specification and claims, are to be understood as being modified in all instances by the term "about" except in any operating example or where otherwise indicated. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

Moreover, it should be understood that any numerical range described herein is intended to include all sub-ranges subsumed therein. For example, a range of "1 to 10" is intended to include all subranges between (and inclusive of) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value equal to or less than 10.

The use of the singular includes the plural and plural encompasses singular, unless specifically stated otherwise. In addition, the use of "or" means "and/or" unless specifically stated otherwise, even though "and/or" may be explicitly used in certain instances.

The term "polymer" is meant to include prepolymers, homopolymers, copolymers and oligomers.

Embodiments of the present disclosure relate to generating a structural object using 3D printing. A 3D object may be produced by depositing at least two co-reactive components onto a substrate to form a continuous portion or layer of the object and then depositing additional portions or layers of the object on the deposited portions or layers below. Layers are deposited consecutively to build up the 3D print object. The coreactive components may be mixed and then deposited or may be deposited separately. When deposited separately, the components may be deposited simultaneously, sequentially or both simultaneously and sequentially.

Deposition and similar terms refer to the application of a printing material comprising a co-reactive or co-reactive composition and/or reactive components thereof onto a substrate (first part of an object) or onto a previously deposited part or layer of an object. Each co-reactive component may comprise monomers, prepolymers, adducts, polymers, and/or crosslinkers that may chemically react with the ingredients of the other co-reactive components.

The at least two co-reactive components may be mixed together and subsequently deposited in the form of a mixture of co-reactive components that react to form portions of the object. For example, the two co-reactive components may be mixed together and deposited as a mixture of co-reactive components that react to form a co-reacted composition by delivering at least two separate streams of the co-reactive components into a mixing device such as a static mixer or dynamic mixer to produce a single stream that is then deposited. The co-reactive components may at least partially react upon deposition of a composition comprising the reaction mixture. The deposited reaction mixture may at least partially react after deposition and may also react with previously deposited portions of the object and/or subsequently deposited portions (e.g., lower or upper layers of the object).

Alternatively, the two co-reactive components may be deposited separately from each other to react upon deposition to form portions of the object. For example, the two co-reactive components may be deposited separately, such as by using an ink printing system, whereby the co-reactive components are deposited beneath and/or adjacent to each other in sufficient proximity so that the two reactive components can react to form portions of the object. As another example, the extruded cross-sectional profile may be heterogeneous, as opposed to homogeneous, such that different portions of the cross-sectional profile may have one of the two co-reactive components and/or may contain a mixture of the two co-reactive components in different molar and/or equivalent ratios.

Furthermore, throughout the 3D printed object, different parts of the object may be formed using two co-reactive components in different proportions, such that the different parts of the object may be characterized by different material properties. For example, some components of the subject may be rigid and other components of the subject may be flexible.

It should be appreciated that the viscosity, reaction rate, and other properties of the coreactive components may be adjusted to control the flow of the coreactive components and/or coreactive compositions (e.g., different monomers) such that the deposited portion and/or object achieves and retains the desired structural integrity after deposition. The viscosity of the co-reactive component may be adjusted by including a solvent (such as, but not limited to, reactive diluents, resins, pigment rheology modifiers), or the co-reactive component may be substantially free of solvent or completely free of solvent. In some embodiments, the solvent may be a solid material such as a resin. In some embodiments, the solvent may be a liquid material. The viscosity of the coreactive component may be adjusted by the inclusion of a filler, or the coreactive component may be substantially free of filler or completely free of filler. The viscosity of the co-reactive component may be adjusted by using components having lower or higher molecular weights. For example, the co-reactive component may include a prepolymer, a monomer, or a combination of a prepolymer and a monomer. The viscosity of the co-reactive component may be adjusted by varying the deposition temperature. The viscosity and temperature profile of the coreactive component may be tailored to the particular deposition method used, such as mixing followed by deposition and/or ink jetting. The viscosity may be affected by the composition itself of the co-reactive components and/or may be controlled by the inclusion of a rheology modifier as described herein.

It may be desirable for the viscosity, yield stress, and/or reaction rate to be such that the composition retains the desired shape after deposition of the co-reactive components. For example, if the viscosity is too low and/or the reaction rate is too slow, the deposited composition may flow in a manner that damages the desired shape of the final object. Similarly, if the viscosity is too high and/or the reaction rate is too fast, the desired shape may also be compromised.

Turning now to the figures, fig. 1 illustrates a system for 3D printing using co-reactive components. The depicted system includes a 3D printer 100 in communication with a computer system 110. Although depicted as physically separate components, computer system 110 may also be fully integrated within 3D printer 100, distributed among a plurality of different electronic devices (including cloud computing environments), or otherwise integrated with 3D printer 100. As used herein, a "3D printer" refers to any device capable of additive manufacturing using computer-generated data files. Such computer-generated data files herein are referred to as "CAD files.

The depicted 3D printer 100 is depicted with a target object 120 in the form of a wedge. The wedge shape includes a trapezoidal surface with a non-planar surface that is configured at least in part with the co-reactive component by the 3D printer 100. The 3D printer 100 also includes a dispenser 130 attached to the movement mechanism 140. As used herein, a "dispenser" may include a dynamic nozzle, a static nozzle, an injection device, a pouring device, a dispensing device, an extrusion device, a spraying device, or any other device capable of providing controlled flow of co-reactive components.

In addition, the movement mechanism 140 is depicted as including a dispenser attached within a track 142 movable along the arm in the X-axis direction and another track set 144 movable in the Y-axis direction. It will be understood, however, that this configuration is provided for purposes of example and explanation only. In additional or alternative configurations, the movement mechanism 140 may include any system capable of controlling the positioning of the dispenser 130 relative to the target object 120, including but not limited to a system that moves the target object 120 relative to the dispenser 130.

Further, 3D printer 100 is coupled to one or more containers 152 (a-e) of co-reactive components. In the depicted example, the co-reactive components are accessed through an optional manifold 150 that allows a user to select a desired container 152 (a-e) from which to extract the co-reactive components. It will be appreciated, however, that the depicted system for 3D printing is merely exemplary. For example, in alternative cases, the system may utilize different configurations of co-reactive components and optional manifold 150, or may not include optional manifold 150 at all.

FIG. 2 shows a schematic diagram of a computer system for thermoset 3D printing. Computer system 110 is shown in communication with 3D printer 100. In addition, various modules or units of 3D print design software 200 are depicted as being executed by computer system 110. Specifically, the 3D print design software 200 is depicted as including a tool path generation unit 240, a flow rate processing unit 242, a dispenser control unit 244, and a materials database 246. The tool path generation unit 240 is configured to generate a tool path and modify it in machine language.

The depicted computer system for thermoset 3D printing is further shown as including a first coreactive component container 152a and a second coreactive component container 152b fed directly into the 3D printer 100. Accordingly, 3D printer 100 may extract coreactive components from first coreactive component container 152a and second coreactive component container 152b as desired. However, it will be appreciated that this configuration is merely exemplary, and in additional or alternative embodiments, different configurations of co-reactive component containers may be utilized to provide co-reactive components to 3D printer 100.

As used herein, a "module" includes computer executable code and/or computer hardware that performs a particular function. Those skilled in the art will appreciate that the differences between the different modules are at least partially arbitrary, and that the modules may be combined and divided in other ways and still remain within the scope of the present disclosure. Accordingly, the description of components as "modules" is provided for clarity and explanation only and should not be construed as representing any particular structure requiring computer executable code and/or computer hardware unless explicitly stated otherwise. In this specification, the terms "unit", "component", "agent", "manager", "service", "engine", "virtual machine" and the like may also be used similarly.

The computer system 110 also includes one or more processors 210 and one or more computer storage media 220 having stored thereon executable instructions that, when executed by the one or more processors 210, configure the computer system 110 to perform various actions. For example, computer system 110 may receive an indication to cause 3D printer 100 to print a non-planar surface. As used herein, "indication" includes any form of input received by computer system 110. For example, the indication may include manual input by a user, automatic actions performed by computer system 110 or another remote computer system, execution of a software application, selection of a user interface element within a graphical user interface, receipt of a data file, or any other form of input that causes computer system 110 to perform a further action. Additionally, as used herein, a non-planar surface includes any surface that decreases in thickness toward a particular end, such as an angled and/or beveled surface. For example, wedge-shaped target object 120 includes a non-planar surface. Thus, a non-planar surface includes a surface that is not planar with respect to the bottom surface of the target object.

Upon receipt of an indication by computer system 110 to print a non-planar surface of target object 120, tool path generation unit 240 generates a tool path to additively fabricate target object 120. As used herein, a "tool path" refers to a path of the dispenser 130 when the dispenser is manufacturing the target object 120. In addition, "tool path" also refers to the speed and/or flow rate of dispenser 130 when the dispenser is producing target object 120. The tool path generation unit 240 generates a tool path such that the co-reactive material is dispensed from the dispenser 130 at a rate and along a path that will produce the target object 120.

In some cases, the tool path may require the dispenser 130 to layer the co-reactive material on top of itself. The flow rate processing unit 242 and the dispenser control unit 244 calculate a target flow rate to ensure that the co-reactive materials are properly bonded between the different layers. Such calculations may take into account the reaction time of the co-reactive material such that the layers are placed on top of each other before the lower layers have time to fully cure. Thus, the generation of the first tool path may be based at least in part on the target flow rate. As explained above, this information regarding the amount of time that the different co-reactive components remain reactive is provided by the materials database 246.

As used herein, a "flow rate" (also referred to as an "extrusion rate") includes a rate at which one or more components of a material are dispensed from dispenser 130. The flow rate may be controlled by the assembly. For example, the tool path generation unit 240 includes a flow rate processing unit 242 that determines and controls a target flow rate for dispensing the co-reactive material to create the target object 120. In some embodiments, the flow rate processing unit 242 may be configured to open and/or close one or more valves at the distributor 130, and/or control the flow rate based on an E command (which invokes a system editor to edit a statement in the stack). In some embodiments, the dispenser control unit 244 may be configured to control the linear movement of the dispenser 130.

The flow rate processing unit 242 may be configured to manipulate the flow rate of the co-reactive material by changing the properties of the co-reactive components within the co-reactive material while the target object 120 is being manufactured. It will be appreciated that the viscosity, reaction rate, and other properties of the co-reactive components may be adjusted to control the flow of the co-reactive components and/or the thermosetting composition such that the deposited portion and/or object reaches and retains the desired structural integrity after deposition. The viscosity of the co-reactive component may be adjusted by the inclusion of a solvent, or the co-reactive component may be substantially solvent-free or completely solvent-free. The viscosity of the coreactive component may be adjusted by the inclusion of a filler, or the coreactive component may be substantially free of filler or completely free of filler. The viscosity of the co-reactive component may be adjusted by using components having lower or higher molecular weights. For example, the co-reactive component may include a prepolymer, a monomer, or a combination of a prepolymer and a monomer. The viscosity of the co-reactive component may be adjusted by varying the deposition temperature. The viscosity and temperature profile of the coreactive component may be tailored to the particular deposition method used, such as mixing followed by deposition and/or ink jetting. The viscosity may be affected by the composition itself of the co-reactive components and/or may be controlled by the inclusion of a rheology modifier as described herein.

It may be desirable for the viscosity and/or reaction rate to be such that the composition retains the desired shape after deposition of the co-reactive components. For example, if the viscosity is too low and/or the reaction rate is too slow, the deposited composition may flow in a manner that damages the desired shape of the final object. Similarly, if the viscosity is too high and/or the reaction rate is too fast, the desired shape may also be compromised.

For example, the co-reactive components deposited together may each have a viscosity at 25 ℃ and at 0.1s ^-1 The shear rate is 5,000 centipoise (cP) to 5,000,000cP, 50,000cP to 4,000,000cP, or 200,000cP to 2,000,000cP. The co-reactive components that are deposited together may each have a viscosity at 25 ℃ and at 1,000s ^-1 The shear rate is 50 centipoise (cP) to 50,000cP, 100cP to 20,000cP, or 200 to 10,000cP. Viscosity values can be measured using an Anton Paar MCR 301 or 302 rheometer with a gap of 1mm to 2 mm.

In addition, the viscosity and/or reaction rate may be adjusted to control the actual bead size or layer size dispensed by dispenser 130. As used herein, a "bead" includes a layer of material dispensed by dispenser 130 on a tool path. Similarly, "bead size" as used herein includes one or more dimensions of the layer dispensed by dispenser 130. For example, the bead size may include the height of the bead, the radius of the bead, the width of the bead, or any other physical dimension of the bead. It should be understood that although the word "bead" is used herein, the actual layer need not have physical similarity to the shape of a conventional bead.

Additionally or alternatively, the dispenser control unit 250 may adjust characteristics of the 3D printer 100 to achieve a desired flow rate. For example, the dispenser control unit 250 may cause the dispenser 130 to travel faster or slower in order to achieve a desired bead size, deposition rate, viscosity, and/or reaction rate. For example, if the dispenser 130 dispenses the co-reactive material at a constant rate and the dispenser control unit 250 causes the dispenser to travel at a faster rate during deposition, the resulting bead size will be smaller. Similarly, the dispenser control unit 250 may cause the dispenser 130 to dispense the co-reactive material at a higher or lower rate based on a desired flow rate and/or bead size. Thus, the flow rate processing unit 242 may adjust the nature of the co-reactive components within the material and/or the dispenser control unit 250 may adjust the mechanical operation of the 3D printer 100 to achieve a desired flow rate and/or bead size.

In some configurations, 3D printer 100 may be capable of manufacturing target object 120 from a variety of different types of materials. These different materials may include different combinations of co-reactive components. For example, FIG. 1 depicts one or more containers 152 (a-e) of co-reactive components, each of which may include different types of co-reactive components. Upon receiving the indication of the material, the tool path generation unit 240 accesses the characteristics of the material from the material database 246. In some cases, the indication of the material includes a particular mixture of co-reactive components, such as provided by one or more containers 152 (a-e) of co-reactive components. The characteristics of the material include the viscosity of the material and/or various other properties related to the reactivity of the material. Using information from the materials database 246 and the processes described herein, the tool path generation unit 240 uses characteristics of the materials to determine a target flow rate and/or bead size.

Additionally, in some configurations, the co-reactive components may utilize an external stimulus, such as UV light, during the course of the reaction. In this case, the 3D printer 100 may include a UV light source controllable by the computer system 110. The 3D printer 100 may be configured to dispense co-reactive materials and cure the materials with a UV light source. The computer system 110 may similarly implement various other stimuli such that the stimulus is applied to the coreactive material during and/or after dispensing of the coreactive material.

Returning now to printing of the non-planar surface of target object 120, 3D print design software 200 may calculate a number of different bead sizes to create the non-planar surface using a thermoset component. In particular, conventional methods for creating a non-planar surface using thermoplastics cause a saw-tooth-like step pattern in which the thermoset tool path extends down the non-planar surface. In contrast, 3D print design software 200 may print the non-planar surface of target object 120 using different sequentially smaller bead sizes and controlling the viscosity of the co-reactive material to create a smooth non-planar surface. In some embodiments, one or more attributes associated with different sequentially smaller bead sizes are determined based on the angle of the non-planar surface. In some embodiments, the properties associated with different sequentially smaller bead sizes are determined based on the top layer and/or the height (i.e., z-axis) configuration of the layer variation. The one or more properties may include, but are not limited to, bead width, nozzle height, travel speed, and/or extrusion amount.

For example, fig. 3 shows side views of different bead sizes. In the depicted example, the first set of bead sizes 310 is located at the top of the cone 300. The second bead size 320 is smaller than the first set of bead sizes. Similarly, third bead size 330 is smaller than second bead size 320, fourth bead size 340 is smaller than third bead size 330, and fifth bead size 350 is smaller than fourth bead size 340. The beads in turn decrease in size to form a natural cone.

The tool path generation unit 240 may calculate the number of bead sizes required along the tool path by using the geometry and material properties (e.g., viscosity) of the co-reactive materials. For example, the tool path generation unit 240 may identify a cone angle and a length. Using this information, the tool path generation unit 240 may calculate the number and size of different beads required to form the desired cone. For example, the tool path generation unit 240 may identify a maximum bead size and a minimum bead size that the dispenser 130 may create using a particular co-reactive material while maintaining desired material properties. Using these two data points, the tool path generation unit 240 may segment the length of the cone into slightly smaller bead sizes.

For example, the tool path generation unit 240 determines the length of the non-planar surface, determines at least one cone angle associated with the non-planar surface, and calculates the geometric ratio of the bead size differences between adjacent thermoset print lines based on the length of the non-planar surface and the at least one cone angle. The ratio is selected to achieve a desired surface angle. For example, the tool path generation unit 240 may identify a desired height of each sequential bead size using a tangent ratio of cone angles. Using this concept, the tool path generation unit 240 may create a command to generate the plurality of different bead sizes at specific locations within the print area. As used herein, a print zone includes a physical area in which the 3D printer 100 is capable of dispensing co-reactive materials.

For example, FIG. 4 shows different bead sizes 410 (a-d) along the tool path 400. In particular, the tool path generation unit 240 calculates the bead sizes 410 (a-d) required to achieve the desired cone. The tool path generation unit 240 generates a tool path 400 configured to sequentially dispense the desired bead sizes 410 (a-d) along the tool path 400.

For example, the tool path generation unit 240 may generate the tool path 400 that dispenses the co-reactive material at a constant rate and changes its speed. Thus, the tool path generation unit 240 may create a command to change the speed of the dispenser 130 within the three-dimensional printer 100, wherein the change in speed conforms to the desired bead size. For example, the dispenser 130 may move at a first speed when creating the bead size 410a, and then the dispenser 130 may move at a faster speed when creating the bead size 410b, such that a smaller bead size 410b is created. Thus, in general, an increase in velocity is associated with a smaller bead size. For each sequential bead size 410 (a-d), the dispenser 130 may be continuously moved at a faster rate such that the bead sizes sequentially decrease along the non-planar surface of the target object 120.

Additionally or alternatively, the tool path generation unit 240 may create a command to change the flow rate of the thermoset material from the three-dimensional printer 100, wherein the change in flow rate conforms to the desired bead size. For example, the tool path generation unit 240 may adjust the flow of co-reactive material along the tool path 400 such that a relatively higher flow rate is used to create the bead size 410a and a relatively lower flow rate is used to create the bead size 410b. Thus, a higher flow rate may be associated with a larger bead size, while a relatively lower flow rate may be associated with a relatively smaller bead size. It will be appreciated that a variety of different methods may be used, alone or in combination, to manipulate the bead size of the co-reactive material dispensed from the dispenser 130.

Fig. 5 illustrates an alternative configuration for varying bead sizes along multiple tool paths 500 (a-h). In the example depicted here, the tool path generation unit 240 generates tool paths 500 (a-h) that run parallel to the cone and continuously reduce the bead size along the cone. In the example of FIG. 4, the bead sizes 410 (a-d) are substantially discrete because each row running perpendicular to the cone is a substantially uniform bead size 410 (a-d). In contrast, in fig. 5, the bead size continues to decrease along the length of the particular tool path 500 (a-h). Thus, it will be appreciated that, in view of the present disclosure, the bead size may be adjusted in a number of different ways to create a non-planar surface.

Fig. 6A illustrates a side view of different bead sizes along a non-planar surface 600 of a target object 120. Side view depicts an exemplary bead size that is perfectly circular. Those skilled in the art will appreciate that once dispensed, the co-reactive material will not remain in a perfectly circular shape. However, for purposes of example and explanation, sequential bead sizes are depicted. Fig. 6B illustrates another side view of a different bead size along a non-planar surface 600. In the example depicted here, the co-reactive beads begin to settle, as indicated by the viscosity of the co-reactive material. Fig. 6C shows another side view of a different bead size along a non-planar surface 600. Fig. 6C depicts the co-reactive material after the individual beads have settled into a smooth non-planar surface 600.

In some embodiments, based on the desired non-planar surface dimensions, the computer system 110 is configured to determine a bead width, a nozzle height, a travel speed, and/or an extrusion amount, and based on the determined bead width, nozzle height, travel speed, and/or extrusion amount, the computer system 110 generates commands to cause the printer 100 to dispense the beads according to the commands, thereby creating the desired cone shape. Fig. 8 illustrates an example of the dimensions of a desired non-planar surface. Based on the desired non-planar surface dimensions, bead width, nozzle height, travel speed, and/or extrusion amount may be calculated to cause the printer to create the desired non-planar surface. In some embodiments, the following equation may be used to calculate the bead width W _n Nozzle height h _n Speed of travel f _x And/or extrusion quantity E, where N is the current iteration and NIs the total iteration.

Or h _i -Tan(π-θ)*(x _n -x _n-1 ) Equation (2)

Fig. 7 illustrates a flow chart of steps of a method 700 for dynamically controlling a thermoset three-dimensional (3D) printer. The depicted method includes an act 710 of receiving an indication to print a non-planar surface. Act 710 includes receiving an indication to cause thermoset three-dimensional printer 100 to print a non-planar surface. For example, as depicted and described with respect to fig. 1, computer system 110 may include commands that cause 3D printer 100 to print a target object 120 that includes a non-planar surface 600.

Additionally, method 700 may include an act 720 of calculating a bead size. Act 720 includes calculating a plurality of different bead sizes to create the non-planar surface 600 using a thermoset component. For example, as depicted and described in fig. 1 and 4, the tool path generation unit 240 may identify angles and lengths associated with the cones. Using this information, the tool path generation unit 240 may calculate the positions and bead sizes of the different beads using conventional geometric ratios.

Method 700 may also include an act 730 of creating a command to generate the calculated bead size. Act 730 includes creating a command to generate the plurality of different bead sizes at locations within the print zone. For example, as depicted in fig. 6A-6C, computer system 110 may cause 3D printer 100 to print non-planar surface 600.

Note that although the figures illustrate tapered surfaces, any non-planar surface may be created based on the principles described herein, as the taper is merely a special case of any non-planar surface.

Further, during the course of the experiment, the inventors noted that in some cases, some extrusion errors may be repeated. In some embodiments, the extrusion error profile is identified and parameterized such that the 3D printer may be configured to adjust these parameters to match the rheology indicated.

As gCode is performed, the process segments, the extrusion rate is divided into acceptable segments. However, for different extruded materials, a different natural hysteresis may occur, i.e., the actual extrusion rate lags the intended extrusion rate indicated by the machine-readable command. To mitigate the hysteresis of the extruded material, in some embodiments, a greater extrusion rate is implemented in the ramp down travel than in the ramp up travel. Such embodiments also provide a means of averaging two adjacent extruded beads such that an effective intermediate extrusion rate between the two adjacent extrusion rates is achieved.

Fig. 9-10 illustrate an example embodiment for implementing a greater extrusion rate for a comparison when traveling down a incline than when traveling up a incline. Fig. 9 illustrates an example tool path 900 along a ramp (i.e., tapered surface). The tool path is divided into a plurality of sections A-B, B-C, C-D, D-E, E-F, F-G, G-H, H-I, and so on. Multiple zones A-B, B-C, C-D, D-E, E-F, F-G, G-H, H-I corresponding to different extrusion rates indicated by the commands are shown as different patterns. For example, the extrusion rate indicated by the command in zones A-B is 8.0, shown as bluish green; the extrusion rate indicated by the commands in zones B-C and H-I was 6.0, shown green; the extrusion rate indicated by the commands in zones C-D and G-H was 4.0, shown as yellow; extrusion rates in zones D-E and F-G were 2.0, shown as light orange; and the extrusion rate in zone EF was 0.0, shown as orange.

Note that in practice, the extrusion rate is changed only in a predetermined minimum discrete unit. When the minimum discrete unit is 2.0, as shown in fig. 9-10, the extrusion rate is always a multiple of 2.0. In some cases, the limitation of the smallest discrete units may cause errors and/or defects in the printed 3D object.

Further, natural hysteresis of the extruded material may also cause errors and/or defects in the printed 3D object. In particular, natural hysteresis can cause the actual extrusion rate to be delayed compared to the command. Fig. 10 illustrates the different extrusion rates of the ramp down and up run shown in fig. 9 to compensate for the hysteresis of the extruded material. The top portion of fig. 10 shows the commanded extrusion rate and the actual extrusion rate due to hysteresis in the ramp down of fig. 9. The bottom portion of fig. 10 shows the commanded extrusion rate and the actual extrusion rate due to hysteresis in the ramp up of fig. 9. As shown, the extrusion rate indicated by the command in the ramp down travel is 8.0 (during section a-B), 6.0 (during section B-C), 4.0 (during section C-D), 2.0 (during section D-E); the extrusion rates indicated by the commands in the ramp up run were 0 (during section E' -F), 2.0 (during section F-G), 4.0 (during section G-H), and 6.0 (during section H-I). Thus, the extrusion rate set (e.g., 8.0, 6.0, 4.0, 2.0) indicated by the command in the ramp up travel is greater than the extrusion rate set (e.g., 0, 2.0, 4.0, 6.0) indicated by the command in the ramp down travel.

Further, there is a delay in the actual extrusion rate compared to the extrusion rate indicated by the command due to the hysteresis of the extruded material. As shown in fig. 10, in the downward travel of the ramp, point S is a point before point a, which may be before point a in time and/or physical space. A command for an extrusion rate of 8.0 is issued at point S, however, due to the hysteresis, the actual extrusion rate at point S is 0.00 and does not reach 8.0 until at point a. Similarly, at point B, the command changes the extrusion rate from 8.0 to 6.0; however, the actual extrusion rate at point B remains at 8.0, and the actual extrusion rate does not reach 6.0 until at point B' (the point between B and C). Also, at point C, the command changes the extrusion rate from 6.0 to 4.0; while the actual extrusion rate at point C remains at 6.0 and does not reach 4.0 until at point C' (the point between C and D). Also, at point D, the command changes the extrusion rate from 4.0 to 2.0; the actual extrusion rate at point D remains at 4.0 and does not reach 2.0 until at point D' (the point between D and E).

The same hysteresis occurs in the ramp up, which causes the actual extrusion rate to be 0 at point E ', 0 at point F' (point between E 'and F), 2.0 at point F, 2.0 at point G' (point between F and G), 4.0 at point H '(point between G and H), 4.0 at point H, 6.0 at point I' (point between H and I), and 6.0 at point I.

Referring back to fig. 9, point a and point I are adjacent on a slope (or non-planar surface); similarly, point B is adjacent to point H, point C is adjacent to point G, and point E is adjacent to point E'; point a 'is adjacent to point I', point B 'is adjacent to point H', point C 'is adjacent to point G', and point D 'is adjacent to point F'. Turning now again to fig. 10, the effective average actual extrusion rate at points a and I is 7.0= (8, 0+6.0)/2 due to the different extrusion rates formed in the ramp down and up runs; the effective average actual extrusion rate at points a 'and I' was 7.0= (8.0+6.0)/2; the effective average natural extrusion rate at points B and H was 6.0= (8.0+4.0)/2; the effective average natural extrusion rate at points B 'and H' was 5.0= (6.0+4.0)/2; the effective average actual extrusion rate at points C and G was 4.0= (6.0+2.0)/2; the effective average actual extrusion rate at points C 'and G' was 3.0= (4.0+2.0)/2; the effective average actual extrusion rate at points D and F was 2.0= (4.0+0.0)/2; the effective average actual extrusion rate at points D 'and F' was 1.0= (2.0+0.0)/2; and the effective average actual extrusion rate at points E and E' is 2.0= (2.0+0.0)/2. Thus, while the extrusion rates vary in discrete units of only 2.0, the effective average of adjacent extrusion rates (e.g., 7.0, 6.0, 5.0, 4.0, 3.0, 2.0, and 1.0) provides finer resolution.

Note that the numbers 8.0, 6.0, 4.0, 2.0 for expressing the extrusion rates are merely examples. The same principles described above apply regardless of the exact number of the smallest discrete units of extrusion rate, and the effective average extrusion rate will provide finer resolution that is finer than the smallest discrete units of extrusion rate.

Having the extrusion rate of the ramp down travel greater than the extrusion rate of the ramp up travel is merely an example of an embodiment that may mitigate or diffuse errors or imperfections of adjacent tool paths on the tapered surface. The principles described herein may also be implemented to mitigate and/or diffuse errors and/or imperfections that occur at adjacent tool paths or that are caused by hysteresis of extruded material in the same tool path on any non-planar surface.

Fig. 11 shows an example of two adjacent tool paths 1110 and 1120. The extrusion rate at the current location 1122 is calculated based on the parameters associated with the adjacent tool path 1110 and the parameters associated with its own tool path 1120. In some embodiments, the diffusion is based on a 3-dimensional (x, y, z three spatial dimensions) or 4-dimensional (x, y, z three spatial dimensions and t, time dimensions) Fuloy-Steinberg filter (Floyd-Steinberg filter) that adds the residual quantitative error of one point to its neighbors. In some embodiments, the computation associated with the spread of errors and/or defects related to the parameters of the adjacent tool path 1110 is referred to as adjacent error spread, and the computation associated with the spread of errors and/or defects related to the parameters of its own tool path 1120 is referred to as forward error spread.

Although shown in fig. 11, adjacent error diffusion and forward error diffusion occur in the same layer of the tool path, the same principles described herein may also be implemented in different layers to adjust the extrusion rate of a first point in a first layer to diffuse errors occurring in a second point in a second layer adjacent to the first layer.

Fig. 12A and 12B show examples of embodiments of error diffusion in different layers. Fig. 12A shows that when printing a tapered surface, the bottom layer typically creates a small gap due to the minimum discrete units of extrusion rate. In some embodiments, the extrusion rate along the tool path may be adjusted to reduce or even eliminate such gaps. Fig. 12B shows the results using the adjusted extrusion rate. As shown in fig. 12B, with the extrusion rate adjusted, most of the gap is eliminated (except for the gap at the rightmost edge).

Further, it is noted that each of the points in the tool path has four dimensions, including 3 dimensions in physical space and a time dimension (not shown). Depending on the actual rate, the time of extrusion change (including the speed of movement of the extruder) can also be adjusted. Thus, the calculation of the extrusion rate is associated not only with the parameters associated with the 3 physical space dimensions, but also with the parameters associated with the time dimension.

These parameters associated with different sizes may be different for different extruded materials. In some embodiments, a separate set of values is compiled for each type of material and stored in a computer readable memory. For example, separate tables may be generated for each type of material. The 3D printer or a computing system coupled to the 3D printer is configured to retrieve different sets of values based on materials used in different print jobs and generate gCode implementing the various error diffusion described above.

In some embodiments, extrusion error diffusion is performed based on an error function that measures the difference between the desired extrusion rate and the actual extrusion rate. The error function is shown in equations (5) and (6) below.

E (x, y, z) =d (x, y, z) -a (x, y, z), equation (5)

Where E is the error function at a particular location (x, y, z), D is the desired extrusion rate, and A is the actual extrusion rate.

As briefly discussed above, in some embodiments, time t is another parameter that may be considered in error diffusion. When considering time t, the error function is shown in equation (1) below.

E (x, y, z, t) =D (x, y, z, t) -A (x, y, z, t), equation (6)

Where E is the error function at a particular location (x, y, z), D is the desired extrusion rate at a particular time t, and A is the actual extrusion rate.

Using the error function in equation (5) and/or equation (6) described above, the total volume is equal to the current error, so that no additional material is added or removed unnecessarily, and a sharpening effect of the detail resolution of the component can be achieved. The error function for error diffusion may be implemented at a computing system connected to the 3D printer or at the printer.

Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the described features or acts described above or the order of acts described above. Rather, the described features and acts are disclosed as example forms of implementing the claims.

The invention may include or utilize a special purpose or general-purpose computer system including computer hardware, such as, for example, one or more processors and system memory, as discussed in more detail below. Embodiments within the scope of the present invention also include physical media and other computer-readable media for carrying or storing computer-executable instructions and/or data structures. Such computer-readable media can be any available media that can be accessed by a general purpose or special purpose computer system. The computer-readable medium storing computer-executable instructions and/or data structures is a computer storage medium. Computer-readable media bearing computer-executable instructions and/or data structures are transmission media. Thus, by way of example, and not limitation, embodiments of the invention may include at least two distinctly different types of computer-readable media: computer storage media and transmission media.

Computer storage media are physical storage media that store computer-executable instructions and/or data structures. Physical storage media include computer hardware, such as RAM, ROM, EEPROM, solid state drives ("SSDs"), flash memory, phase change memory ("PCM"), optical disk storage, magnetic disk storage or other magnetic storage devices, or any other hardware storage device that can be used to store program code in the form of computer-executable instructions or data structures, which can be accessed and executed by a general purpose or special purpose computer system to implement the disclosed functionality of the present invention.

The transmission media may contain network and/or data links, which may be used to carry program code in the form of computer-executable instructions or data structures, and which may be accessed by a general purpose or special purpose computer system. A "network" is defined as one or more data links that enable the transmission of electronic data between computer systems and/or modules and/or other electronic devices. When information is transferred or provided over a network or another communications connection (either hardwired, wireless, or a combination of hardwired or wireless) to a computer system, the computer system may view the connection as a transmission medium. Combinations of the above should also be included within the scope of computer-readable media.

Further, upon reaching various computer system components, program code in the form of computer-executable instructions or data structures can be transferred automatically from transmission media to computer storage media (or vice versa). For example, computer-executable instructions or data structures received over a network or data link may be buffered in RAM within a network interface module (e.g., a "NIC") and then ultimately transferred to computer system RAM and/or less volatile computer storage media at a computer system. Thus, it should be understood that computer storage media may be contained in computer system components that also (or even primarily) utilize transmission media.

Computer-executable instructions comprise, for example, instructions and data which, when executed at one or more processors, cause a general purpose computer system, special purpose computer system, or special purpose processing device to perform a certain function or group of functions. The computer-executable instructions may be binary, intermediate format instructions such as assembly language, or even source code.

Those skilled in the art will appreciate that the invention may be practiced in network computing environments with many types of computer system configurations, including personal computers, desktop computers, laptop computers, message processors, hand-held devices, multiprocessor systems, microprocessor-based or programmable consumer electronics, network PCs, minicomputers, mainframe computers, mobile telephones, PDAs, tablet computers, pagers, routers, switches, and the like. The invention may also be practiced in distributed system environments where local and remote computer systems, which are linked (either by hardwired data links, wireless data links, or by a combination of hardwired and wireless data links) through a network, both perform tasks. Thus, in a distributed system environment, a computer system may contain multiple constituent computer systems. In a distributed system environment, program modules may be located in both local and remote memory storage devices.

Those skilled in the art will also appreciate that the present invention may be practiced in a cloud computing environment. The cloud computing environment may be distributed, but this is not required. In a distributed case, the cloud computing environment may be distributed globally within an organization and/or have components owned across multiple organizations. In this specification and in the following claims, "cloud computing" is defined as a model for enabling on-demand network access to a shared pool of configurable computing resources (e.g., networks, servers, storage, applications, and services). The definition of "cloud computing" is not limited to any other numerous advantages that may be obtained from such a model when properly deployed.

The cloud computing model may be composed of various features such as on-demand self-service, wide network access, resource pooling, fast resilience, quantifiable services, and the like. The cloud computing model may also come in the form of various service models (e.g., software as a service ("SaaS"), platform as a service ("PaaS"), and infrastructure as a service ("IaaS")). The cloud computing model may also be deployed using different deployment models, such as private cloud, community cloud, public cloud, hybrid cloud, and the like.

Some embodiments, for example, a cloud computing environment may include a system including one or more hosts each capable of running one or more virtual machines. During operation, the virtual machine emulates an operational computing system supporting an operating system and possibly one or more other applications. In some embodiments, each host includes a hypervisor that emulates virtual resources of the virtual machine using physical resources that are abstracted from the perspective of the virtual machine. The hypervisor also provides for proper separation between virtual machines. Thus from the perspective of any given virtual machine, the hypervisor provides a false image of the virtual machine interfacing with the physical resource, even though the virtual machine interfaces only with the appearance of the physical resource (e.g., virtual resource). Examples of physical resources include processing power, memory, disk space, network bandwidth, media drives, and the like.

The invention is further described in the following aspects.

According to a first aspect, there is provided a computer system for dynamically controlling a three-dimensional printer, the computer system comprising: one or more processors; and one or more computer-readable media having stored thereon executable instructions that, when executed by the one or more processors, configure the computer system to, preferably according to the method of any one of aspects sixteen to twenty-four: receiving an indication to cause the three-dimensional printer to print a non-planar surface of a three-dimensional object having a particular shape; calculating a plurality of different bead sizes to create the non-planar surface using components of the three-dimensional printer; and creating a command to generate the plurality of different bead sizes or ratios at locations within the print zone.

Aspect two relates to the computer system of aspect one, wherein creating a command to generate the plurality of different bead sizes at specific locations within the print area comprises: a command is created to change the material extrusion rate of the three-dimensional printer, wherein the change in extrusion rate corresponds to a desired bead size or location having a particular height in which one or more beads are to be deposited.

Aspect three relates to the computer system of any one of aspects one or two, wherein calculating a plurality of different bead sizes to create the non-planar surface using components of the three-dimensional printer further comprises: identifying a plurality of parameters related to errors that may be caused by a plurality of constraints of the three-dimensional printer, the plurality of constraints including at least one of: (1) The three-dimensional printer is capable of generating a minimum bead size; or (2) natural hysteresis of the extruded material forming the beads; and calculating a plurality of different bead sizes based on the plurality of parameters.

The fourth aspect relates to the computer system of any one of the first to third aspects, wherein calculating a plurality of different bead sizes to create the non-planar surface using components of the three-dimensional printer further comprises calculating a difference between a desired extrusion rate and an actual extrusion rate.

Aspect five relates to the computer system of any of aspects one to four, wherein calculating a plurality of different bead sizes based on the plurality of parameters comprises calculating a bead size (1) to diffuse a first error caused by the natural hysteresis of the extruded material, (2) to diffuse a second error occurring on an adjacent tool path on a same layer, and/or (3) to diffuse a third error occurring on an adjacent tool path on a different layer.

A sixth aspect relates to the computer system of any of the first to fifth aspects, wherein a first tool path traveling down a slope has a first set of bead sizes, a second tool path traveling up the slope has a second set of bead sizes, and an average size of the first set of bead sizes is greater than an average size of the second set of bead sizes.

A seventh aspect relates to the computer system of the sixth aspect, wherein the first tool path and the second tool path are adjacent on the ramp, and an average effective bead size of the first tool path and the second tool path has a finer resolution than a resolution of the three-dimensional printer.

An eighth aspect relates to the computer system of any of the aspects one to seven, wherein creating a command to generate the plurality of different bead sizes at specific locations within the print area comprises interpolating specific coordinates within the print area.

Aspect nine relates to the computer system of aspect eight, wherein interpolating particular coordinates within the print area comprises determining at least one of a bead width, a nozzle height, a travel speed, or an extrusion amount based on the particular shape of the three-dimensional object.

Aspect ten relates to the computer system of any one of aspects one to nine, wherein the three-dimensional printer is a thermoset printer.

Aspect eleven relates to the computer system of any one of aspects one to ten, wherein the system comprises a three-dimensional printer.

Aspect twelve relates to the computer system of any of aspects one to eleven, wherein a plurality of different bead sizes obtained by adjusting the viscosity, the reaction rate, and/or the composition of the co-reactive components are calculated.

The thirteenth aspect relates to the computer system of any one of the aspects one to twelve, wherein calculating a plurality of different bead sizes includes identifying a taper (ramp) angle and/or length of the surface and calculating a number and size of different beads required to form a desired taper (ramp).

The fourteenth aspect relates to the computer system of any one of the aspects one to thirteenth, wherein calculating the plurality of different bead sizes comprises a tool path and/or a tool path running parallel to the cone and continuously decreasing the bead sizes along the cone, wherein each row runs perpendicular to the cone and each row has a different bead size.

Aspect fifteen relates to the computer system of any one of aspects one to fourteen, wherein calculating a plurality of different bead sizes comprises calculating the positions and bead sizes of the different beads, preferably using geometric ratios of cones.

According to a sixteenth aspect, there is provided a computer implemented method for dynamically controlling a three-dimensional printer, the computer implemented method being executed on one or more processors, preferably as defined in any one of the aspects one to fifteen, the computer implemented method comprising: receiving an indication to cause the three-dimensional printer to print a non-planar surface; calculating a plurality of different bead sizes to create the non-planar surface; and creating a command to generate the plurality of different bead sizes at specific locations within the print zone.

Seventeenth aspect relates to the computer system of the sixteenth aspect, wherein creating a command to generate the plurality of different bead sizes at specific locations within the print area comprises: a command is created to change the material extrusion rate of the three-dimensional printer, wherein the change in extrusion rate conforms to a desired bead size.

Aspect eighteenth relates to the computer system of any of aspects sixteen or seventeen, wherein a higher extrusion rate is associated with a larger bead size.

The nineteenth aspect relates to the computer system of any one of the sixteenth or seventeenth aspects, wherein the method is capable of dynamically controlling and adjusting the flow rate of the co-reactive components, the pump speed, the gantry speed, and/or the tool path to generate the plurality of different bead sizes at specific locations within the print zone.

Aspect twenty relates to the computer system of any one of aspects sixteen to nineteenth, wherein creating a command to generate the plurality of different bead sizes at specific locations within the print area comprises: a command is created to change the speed of a dispenser within the three-dimensional printer, wherein the change in speed conforms to a desired bead size.

Aspect twenty-one relates to the computer system of any one of aspects sixteen to twenty-one, wherein the increase in speed is associated with a smaller bead size.

Aspect twenty-two relates to the computer system of any one of aspects sixteen to twenty-one, further comprising causing the three-dimensional printer to dispense the plurality of different bead sizes at specific locations within the print zone.

The twenty-third aspect relates to the computer system of any one of the twenty-first to twenty-second aspects, wherein the non-planar surface is a non-planar surface, and calculating a plurality of different bead sizes to create the non-planar surface using a three-dimensional assembly comprises: determining a length of the non-planar surface; determining at least one cone angle associated with the non-planar surface; and calculating a geometric ratio of bead size differences between adjacent thermoset printed rows based on the length of the non-planar surface and the at least one taper angle.

Aspect twenty-four relates to the computer system of any of aspects sixteen to twenty-three, wherein creating a command to generate the plurality of different bead sizes at specific locations within the print zone comprises interpolating specific coordinates within the print zone.

Aspect twenty-five relates to the computer system of aspect twenty-four, wherein interpolating particular coordinates within the print zone includes calculating at least one of bead width, nozzle height, travel speed, or extrusion amount, and creating a command to cause the three-dimensional printer to print based on the calculated bead width, nozzle height, travel speed, or extrusion amount.

According to a twenty-sixth aspect, a computer-readable medium comprising one or more physical computer-readable storage media having stored thereon executable instructions that, when executed by a processor, cause a computer system to perform a method for dynamically controlling a three-dimensional printer, preferably a method as defined in any of the sixteen to twenty-fourth aspects, the method comprising: receiving an indication to cause the three-dimensional printer to print a non-planar surface; calculating a plurality of different bead sizes to create the non-planar surface using components of the three-dimensional printer; and creating a command to generate the plurality of different bead sizes at specific locations within the print zone.

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims (20)

1. A computer system for dynamically controlling a three-dimensional printer, the computer system comprising:

one or more processors; and

one or more computer-readable media having stored thereon executable instructions that, when executed by the one or more processors, configure the computer system to:

receiving an indication to cause the three-dimensional printer to print a non-planar surface of a three-dimensional object having a particular shape;

calculating a plurality of different bead sizes or ratios to create the non-planar surface using components of the three-dimensional printer; and is also provided with

A command is created to generate the plurality of different bead sizes or ratios at locations within the print zone.

2. The computer system of claim 1, wherein creating a command to generate the plurality of different bead sizes or ratios at specific locations within the print area comprises:

a command is created to change the material extrusion rate of the three-dimensional printer, wherein the change in extrusion rate corresponds to a desired bead size or location having a particular height in which one or more beads are to be deposited.

3. The computer system of any one of claims 1-2, wherein calculating a plurality of different bead sizes or ratios to create the non-planar surface using components of the three-dimensional printer further comprises:

identifying a plurality of parameters related to errors that may be caused by a plurality of constraints of the three-dimensional printer, the plurality of constraints including at least one of: (1) The three-dimensional printer is capable of generating a minimum bead size; or (2) natural hysteresis of the extruded material forming the beads; and

a plurality of different bead sizes or ratios are calculated based on the plurality of parameters.

4. The computer system of any of claims 1-3, wherein calculating a plurality of different bead sizes or ratios to create the non-planar surface using components of the three-dimensional printer further comprises calculating a difference between a desired extrusion rate and an actual extrusion rate.

5. The computer system of any of claims 1-4, wherein calculating a plurality of different bead sizes or ratios based on the plurality of parameters comprises calculating a bead size (1) to diffuse a first error caused by the natural hysteresis of the extruded material, (2) to diffuse a second error occurring on an adjacent tool path on the same layer, or (3) to diffuse a third error occurring on an adjacent tool path on a different layer.

6. The computer system of any one of claims 1 to 5, wherein a first tool path traveling down a slope has a first set of bead sizes, a second tool path traveling up the slope has a second set of bead sizes, and an average size of the first set of bead sizes is greater than an average size of the second set of bead sizes.

7. The computer system of any of claims 1-6, wherein the first tool path and the second tool path are adjacent on the ramp, and an average effective bead size of the first tool path and the second tool path has a finer resolution than a resolution of the three-dimensional printer.

8. The computer system of any of claims 1 to 7, wherein creating a command to generate the plurality of different bead sizes at specific locations within the print area comprises interpolating specific coordinates within the print area.

9. The computer system of any one of claims 1 to 8, wherein interpolating particular coordinates within the print area comprises determining at least one of a bead width, a nozzle height, a travel speed, or an extrusion amount based on the particular shape of the three-dimensional object.

10. The computer system of any one of claims 1 to 9, wherein the three-dimensional printer is a thermoset printer.

11. A computer-implemented method for dynamically controlling a three-dimensional printer, the computer-implemented method being performed on one or more processors, the computer-implemented method comprising:

receiving an indication to cause the three-dimensional printer to print a non-planar surface of a three-dimensional object having a particular shape;

calculating a plurality of different bead sizes or ratios to create the non-planar surface; and

a command is created to generate the plurality of different bead sizes or ratios at locations within the print zone.

12. The computer-implemented method of claim 11, wherein creating a command to generate the plurality of different bead sizes or ratios at specific locations within the print zone comprises:

a command is created to change the material extrusion rate of the three-dimensional printer, wherein the change in extrusion rate conforms to a desired bead size.

13. The computer-implemented method of any of claims 11-12, wherein a higher extrusion rate is associated with a larger bead size.

14. The computer-implemented method of any of claims 11-13, wherein creating a command to generate the plurality of different bead sizes at specific locations within the print zone comprises:

a command is created to change the speed of a dispenser within the three-dimensional printer, wherein the change in speed conforms to a desired bead size.

15. The computer-implemented method of any of claims 11-14, wherein the increase in velocity is associated with a smaller bead size.

16. The computer-implemented method of any of claims 11-15, further comprising causing the three-dimensional printer to dispense the plurality of different bead sizes at specific locations within the print zone.

17. The computer-implemented method of any of claims 11-16, wherein calculating a plurality of different bead sizes or ratios to create the non-planar surface using a three-dimensional component comprises:

determining a length of the non-planar surface;

determining at least one cone angle associated with the non-planar surface; and

Based on the length of the non-planar surface and the at least one cone angle, a geometric ratio of bead size differences between adjacent print lines is calculated.

18. The computer-implemented method of any of claims 11-17, wherein creating a command to generate the plurality of different bead sizes at specific locations within the print zone comprises interpolating specific coordinates within the print zone.

19. The computer-implemented method of any of claims 11-18, wherein interpolating particular coordinates within the print zone includes calculating at least one of bead width, nozzle height, travel speed, or extrusion amount, and creating a command to cause the three-dimensional printer to print based on the calculated bead width, nozzle height, travel speed, or extrusion amount.

20. A computer-readable medium comprising one or more physical computer-readable storage media having stored thereon executable instructions that, when executed by a processor, cause a computer system to perform a method for dynamically controlling a three-dimensional printer, the method comprising:

Receiving an indication to cause the three-dimensional printer to print a non-planar surface of a three-dimensional object having a particular shape;

calculating a plurality of different bead sizes or ratios to create the non-planar surface using components of the three-dimensional printer; and

a command is created to generate the plurality of different bead sizes or ratios at locations within the print zone.