Tool path planning process for component by layered manufacture

A method for generating at least one tool path within a layer region for layered manufacturing, wherein said layer region includes a material region disposed within an outer perimeter, wherein said tool path has an associated offset distance, the method comprising the steps of:

• offsetting said outer perimeter inward toward said material region by about said tool path offset to form a first outer boundary;
• identifying at least one outer perimeter vertex;
• identifying a first outer boundary vertex on said first outer boundary derived from said outer perimeter vertex;
• relocating said first outer boundary vertex from an original position to a relocated position disposed closer to said outer perimeter vertex than said original position, such that said first outer boundary is modified by being moved closer to said outer perimeter vertex;
• and
• generating at least one tool path within said relocated first outer boundary.

A method for generating at least one tool path portion within a layer region for layered manufacturing, wherein the layer region has at least a first outer perimeter portion and a second outer perimeter portion meeting at an angle of less than 180 degrees to each other at an outer perimeter vertex, wherein said layer region has a material portion between said first and second perimeter portions, wherein said tool path has an associated offset corresponding to about half of an associated tool path bead width, wherein said tool path offset and first perimeter define a first outer boundary first leg substantially parallel to said first perimeter and disposed in said material portion, wherein said tool path offset and said second perimeter define a first outer boundary second leg substantially parallel to said second perimeter and disposed in said material portion, wherein said first outer boundary first leg and first outer boundary second leg intersect at a first outer boundary vertex, wherein the method comprises the steps of:

• generating a modified first outer boundary vertex point which lies between said perimeter vertex point and said first outer boundary vertex point;
• generating a first leg tool path portion along a portion of said first outer boundary first leg;
• generating a second leg tool path portion along a portion of said first outer boundary second leg;
• generating a third tool path portion extending from said first leg tool path portion to said modified first outer boundary vertex point;
• and
• generating a fourth tool path portion extending from said modified first outer boundary vertex point and extending to said second leg tool path portion, such that said tool path extends nearer said perimeter vertex at said modified first outer boundary vertex point than at said first outer boundary vertex point.

A method for generating at least one tool path within a layer region for layered manufacturing, wherein said layer region has at least a first contour tool path first leg and a first contour tool path second leg, wherein said first contour tool path first and second legs, when extended, meet at an internal angle of less than 180 degrees at a first contour tool path vertex, wherein said layer has a material portion between said first contour tool path first and second legs, wherein said tool path has an associated offset corresponding to about half of an associated tool path bead width, wherein said tool path offset and first contour tool path first leg define a first contour boundary first leg parallel to said first contour tool path first leg and disposed in said material portion, wherein said tool path and said first contour tool path second leg define a first contour boundary second leg parallel to said first contour tool path second leg and disposed in said material portion, wherein said first contour boundary first and second legs intersect at a first internal boundary vertex, wherein the method comprises the steps of:

• generating a modified internal vertex point which lies between said contour tool path vertex point and said first boundary vertex point;
• generating a first tool path leg portion along a portion of said first contour boundary first leg;
• generating a second tool path leg portion along a portion of said first contour boundary second leg;
• generating a third tool path portion extending from said first tool path leg portion to said modified internal vertex point;
• and
• generating a fourth tool path portion extending from said modified internal vertex point and extending to said second tool path leg portion,
• such that said tool path extends nearer said contour vertex point than said first boundary vertex point.

A method for generating an additive tool path to form a perimeter vertex by layered manufacturing, wherein the tool path has an associated tool path offset, the method comprising the steps of:

• obtaining a first data representation of said perimeter vertex;
• obtaining a second data representation of a first tool path offset inward from said perimeter vertex;
• identifying at least one perimeter point on a tip of said perimeter vertex;
• selecting a first tool path point from said second data representation that was offset inward from said perimeter vertex tip point;
• and
• moving said first tool path point toward said perimeter vertex point, such that said first tool path point is located closer to said perimeter vertex point.

A method for generating at least one tool path within a design layer region for layered manufacturing, wherein said design layer region has an inner void, wherein said design layer region has an outer perimeter and at least one inner perimeter associated with said inner void, wherein said design layer region has a material region between said outer perimeter and said inner perimeter, wherein said tool path has an associated offset corresponding to about half of an associated tool path bead width, wherein said tool path has an origin, the method comprising the steps

• (a) establishing an inner perimeter boundary disposed at about said offset distance from said inner void perimeter toward said material region, such that a first margin is established about said inner void within said material region;
• (b) generating said tool path along a line until said line intersects said inner perimeter boundary at an intersection point;
• (c) if said intersection point is the first intersection of said tool path with said inner perimeter boundary, executing step (d), otherwise executing step (e);
• (d) continuing said tool path in a direction following said inner perimeter boundary in a direction such that said tool path initially proceeds most toward said tool path origin;
• and
• (e) continuing said tool path in a direction following said inner perimeter boundary in a direction such that said tool path initially proceeds most away from said tool path origin.

A method for generating at least one tool path within a design layer region for layered manufacturing, wherein said design layer region has an inner void, wherein said design layer region has an outer perimeter and at least one inner perimeter associated with said inner void, wherein said design layer region has a material portion between said outer perimeter and said inner perimeter, wherein said tool path has an associated offset corresponding to about half of an associated tool path bead width, wherein said tool path has an origin, the method comprising the steps of:

• (a) establishing a first axis in said design layer relative to said outer perimeter, thereby establishing a second axis orthogonal to said first axis;
• (b) generating an outer perimeter boundary into said material region, having a distance from said outer perimeter of about said offset distance;
• (c) generating an inner perimeter boundary into said material region, having a distance from said inner perimeter of about said offset distance;
• (d) generating a plurality of parallel guides parallel to said first axis;
• (e) establishing a tool path origin point, and initializing said tool path generation at said origin point parallel to said first axis;
• (f) continuing generating said tool path line until said tool path intersects a line selected from the group of outer perimeter boundaries, inner perimeter boundaries, and guide lines;
• then, executing step (g);
• (g) if said step (f) tool path intersection is an outer perimeter boundary intersection, then generating said tool path to follow said outer perimeter boundary in a direction initially most away from said origin, then executing step (f);
• (h) if said step (f) tool path intersection is an inner perimeter boundary intersection, and if said step (f) intersection is the first intersection with said inner perimeter boundary, then generating said tool path to follow said inner perimeter boundary in a direction initially most toward said origin, then executing step (f);
• (i) if said tool path intersection is an inner perimeter boundary intersection, and if said intersection is not the first intersection with said inner perimeter boundary, then generating said tool path to follow said inner perimeter boundary in a direction initially most away from said origin, then executing step (f);
• (j) if said step (f) tool path intersection is a guide line intersection, then generating said tool path along said guide line in a direction most initially toward said origin, then executing step (f);
• and
• (k) repeating steps (f) through (j) until no more contiguous travel of unvisited guide lines is possible.

A method for generating tool paths for a layer for layered manufacturing comprising the steps of:

• obtaining an outer boundary for said layer;
• forming a plurality of substantially parallel raster tool path pairs, said pairs having a first segment coupled at a first raster vertex to a second segment, said second segment coupled at a second vertex to a third segment, wherein said second segment is substantially parallel to said outer boundary, wherein said first and second segments are substantially parallel to each other and to said raster tool path pairs;
• wherein said raster tool path pairs are separated by inter-pair lines disposed between a first segment of a first raster pair and a third segment of a second, adjacent raster pair;
• wherein an inter-pair intersection point is formed by a projection extension of said inter-pair line to said outer boundary;
• and
• positioning first and second raster vertices disposed on either side of said intra-pair line at about one half of said raster tool path bead width from said inter-pair intersection point.