Methods, systems, and apparatus include computer programs encoded on a computer-readable storage medium, including a method for 3D printing without preprocessing a CAD model before delivery to a 3D printer. The CAD model for a design to be printed is received by a 3D printer. Instructions are generated for printing the first slice. While the instructions are used to start printing the CAD model, dynamic real-time slicing is performed on a remaining portion of the CAD model. Preprocessed data, model analysis information or real-time feedback is received during the printing of a respective slice. A next slice is identified, and slicing parameters are adjusted, including adjusting a slicing parameter for the next slice. Instructions for printing the next slice are generated. The next slice is printed based on the generated instructions. Dynamic real-time slicing is repeated to generate a then next slice and associated printing instructions.

One embodiment of the invention is a slicing engine that generates two or more slices of a virtual 3D model given a slice plane. The slicing engine then determines connection points on each of the slices that indicate how the 3D model is to be reconnected by the user when the 3D model is fabricated. The slicing engine also determines an optimized layout for the various slices of the 3D model on fabrication material for minimal use of the material. The user is then able to “print” the layout on the fabrication material via 3D printers, and connect the various printed slices according to the connection points to build a physical representation of the 3D model.

A robot system is configured to fabricate three-dimensional (3D) objects using closed-loop, computer vision-based control. The robot system initiates fabrication based on a set of fabrication paths along which material is to be deposited. During deposition of material, the robot system captures video data and processes that data to determine the specific locations where the material is deposited. Based on these locations, the robot system adjusts future deposition locations to compensate for deviations from the fabrication paths. Additionally, because the robot system includes a 6-axis robotic arm, the robot system can deposit material at any locations, along any pathway, or across any surface. Accordingly, the robot system is capable of fabricating a 3D object with multiple non-parallel, non-horizontal, and/or non-planar layers.

An apparatus and methods for generating geometric data for use in an additive manufacturing process. The apparatus includes a processing unit. The processing unit may be arranged for receiving data defining surface geometry of a plurality of objects to be built together in an additive manufacturing process, providing a user interface that allows a user to define a location of each object within a common build volume and carrying out a slicing operation on at least one of the objects located in the common build volume independently from another one of objects located in the common build volume. The slicing operation determines sections of the at least one object to be built in the additive manufacturing process. In one embodiment, the objects are defined in a hierarchical data structure. Supports for supporting the objects during the build may be defined with reference to a 2-dimensional support cross-section.

Some embodiments facilitate creation of an industrial asset item via a rotary additive manufacturing process. For example, a build plate may rotate about a vertical axis and move, relative to a print arm, along the vertical axis during printing. An industrial asset item definition data store may contain at least one electronic record defining the industrial asset item. A frame creation computer processor may slice the data defining the industrial asset item to create a series of two-dimensional, locally linear frames helically arranged as a spiral staircase of steps (and each step may be oriented normal to the vertical axis. Indications of the series of two-dimensional frames may then be output to be provided to a rotary three-dimensional printer.

An additive manufacturing method includes segmenting a CAD file of a component along a build interface to define at least a first component segment and a second component segment, each of the first component segment and the second component segment sized to fit within an additive manufacturing build chamber; additive manufacturing the first component segment and the second component segment within the build chamber; and bonding the first component segment and the second component segment to form the component.

An additive manufacturing method includes segmenting a CAD file of an component along an build interface to define at least a first component segment and a second component segment each of the first component segment and the second component segment sized to fit within an additive manufacturing build chamber; additive manufacturing the first component segment and the second component segment within the build chamber; and bonding the first component segment and the second component segment to form the component.

An additive manufacturing method includes segmenting a CAD file of a component along a build interface to define at least a first component segment and a second component segment, each of the first component segment and the second component segment sized to fit within an additive manufacturing build chamber; additive manufacturing the first component segment and the second component segment within the build chamber; and bonding the first component segment and the second component segment to form the component.

An additive manufacturing method includes segmenting a CAD file of a component along a build interface to define at least a first component segment and a second component segment, each of the first component segment and the second component segment sized to fit within an additive manufacturing build chamber; additive manufacturing the first component segment and the second component segment within the build chamber; and bonding the first component segment and the second component segment to form the component.

Varying a slicing thickness for 3D modeling may include: receiving 3D modeling data from a user device; slicing the 3D modeling data, in accordance with a first thickness, into multiple cross-sections; calculating a complexity of one or more of the multiple cross-sections; and determining a slicing thickness of the 3D modeling data based on the complexity of the one or more of the multiple cross-sections.