3D Printing – Riley Reese, Hemant Bheda, Wiener Mondesir, Arevo Inc
Abstract for “Method for monitoring additive manufacturing processes for detection and correction of in-situ defects”
The present invention provides a system for monitoring and identifying real-time defects in an object made by additive manufacturing. The present invention also provides an in-situ solution to such defects through a plurality functional tool heads that have freedom of movement in arbitrary planes or approaches. These functional tool heads can be controlled independently and automatically based on feedback from the printing process. The present invention also provides a method for analysing defected data from detection devices, and correcting tool paths instructions and object models in-situ while constructing a 3D object. The build report displays in 3D space the structure and inherent properties of the final built object, along with details of any corrections or uncorrected errors. The build report is a great tool for improving the 3D printing process of subsequent objects.
Background for “Method for monitoring additive manufacturing processes for detection and correction of in-situ defects”
The additive manufacturing process, also known as three-dimensional printing of 3D objects, is well-known. Numerous methodologies have been described in prior art, the most common including solid-laser-sintering (?SLS? Stereolithography (?SLA?) is another method. Stereolithography (?SLA?) The deposition of thermoplastic material is part of extrusion-based 3D printing. Extrusion-based 3D printing is most commonly used today for prototyping. It uses materials like ABS (acrylonitrilebutadiene styrene), and PLA (polylactic acids). The technology has advanced to the point that 3D printing can now use higher-end engineering semicrystalline and amorphous plastics as well as metals, ceramics, and materials with better mechanical, chemical and electrical properties. Examples of semi-crystalline polymers include polyetheretherketone (PEEK), polyetherketoneketone (PEKK), etc. Polyphenylsulphone, polyetherimide, and others are examples of amorphous engineering plasticmers.
“Prior art in extrusion-based 3D printing is about extruding filament through an extruder, depositing the extrudate onto a platform and forming a 3D object one layer at a. Time. There is no feedback regarding the build process or the quality of deposition. Defects in 3D object printing can lead to errors in its geometry, i.e. Dimensions or contours) and deficiencies in desired properties (e.g. ”
These defects, errors or characteristics, which are not in accordance with the intended design, such as deviations in filament diameter, feed rate, and nozzle orifice, can result in an inaccurate volume of extrudate deposited; inaccuracy of the print head to follow desired tool path, leading to out of tolerance features; deviations in heating or cooling the material to deposit it, causing defects such as drooping/sagging or reduced crystallinity; delamination; warping or overhangs between the object or the plate These defects, if not corrected can lead to flaws in the printed object such as inadequate mechanical, chemical or thermal properties.
FIG. 1. The software cuts a 3D object file (100), into a number layers (102) by using slicing parameters like filament diameter, nozzle size, layer thickness, fill rate, speed, etc. Each layer receives tool path instructions (104) that are sent to the 3D printer. The 3D printer prints each layer without any way to monitor, correct or detect errors. The printing ceases (108) when the layer printing is complete (106). If not, the method loops back and prints the next layer using the extruder (104)
“The prior art does not provide a quantitative or qualitative report that could inform a 3D printer user about the structure and features of the printed object. It may also guide them in deciding whether to keep the object or throw it away. These reports are also not available to assist in improving the printing process for three-dimensional objects.
There is a need for three-dimensional printing methods that monitor and identify defects in 3D objects while they are being printed. Further, the object can be corrected in-situ as it is printed. A closed-loop slicing system that updates the object model and slicing parameters in-situ based on object geometry and defect data is also needed. Three-dimensional printing has the potential to create a report that displays geometry as well as the features of uncorrected and corrected defects in 3D printing processes. This will allow for improvements in printing.
The present invention improves additive manufacturing by identifying and monitoring defects while a 3D object is being printed. In-situ corrections of defects are made based on quality control feedback during printing. Finally, slicing parameters and objects models are updated based upon the correction. Based on the object property requirements and slicing parameters, a 3D object layer or segment is cut. The tool path instructions for segment and layer are generated, then fed to the 3D printer for printing. The quality of the printed segment, layer or build feature (i.e. Through-hole, contoured section and overhang are all possible. are analyzed for any defects. If the defect can be corrected, a tool path is created for the tool with capabilities such as drilling, milling, heating, extrusion, etc. Attached to a head that is capable of following multi-dimensional paths,
“Next, the object modeling and slicing parameters will be updated based upon analysis of previously printed segments, layers, or build features, as well as corrected defects. The segment, layer or build feature are analyzed and a qualitative and quantitative report is generated. The report logs temperature, speed, material use, and imaging data. After the object has been printed, a final report with property analysis is generated. Final report determines whether the object has the intended properties. Based on in-situ parameter adjustments made during build, it also records modified instructions for the next build.
The present invention has the objective of providing a system that monitors, identifies and corrects defects. It also updates tool path instructions and the object model in-situ during 3D object formation. This effectively adds a closed loop feedback mechanism for part quality.
The present invention provides a method for monitoring, identifying, and correcting defects and updating tool path instructions as well as object model in-situ while 3D objects are being printed. This effectively adds a closed loop feedback mechanism to improve part quality.
“The present invention aims to provide multiple functional tool heads with multi-axes motion mechanism. They can be independently controlled and automatically controlled to perform one or several functions. This is done based on feedback analysis to correct any defects.
“Another objective is the present invention to provide a means of logging real-time events such as identified defects, critical feature measurements and dimensionality.
“Another objective is the invention to generate a report listing all defects in the printed 3D object. The build report can then be used for predicting the properties of the final built part such as mechanical strength and electrical conductivity. To minimize defects in future runs, the build report can be used to optimize build parameters and the tool path.
The following description of embodiments of invention provides a detailed understanding of the invention. A skilled person in the art will know that embodiments of invention can be used with or without these details. Other well-known methods, procedures, and components are not described in detail to avoid confusing aspects of the embodiments.
“It will also be apparent that the invention does not limit itself to these embodiments. Many modifications, variations, substitutions, and equivalents are possible for those skilled in art. They do not have to depart from the spirit or scope of the invention.
The present invention provides an additive manufacturing method to print or build a 3D object/part. It includes, but is not limited, to extrusion-based, fused filament fabrication and droplet based printing methods. The invention also provides a method and system to monitor and correct defects in objects while they are being printed using additive manufacturing. This allows for the production of a 3D object that meets all specifications. ”
Incorrect or incorrectly built parts can happen during additive manufacturing and three-dimensional printing processes. These printing processes can lead to defects in the structural geometry and other problems that may affect the part’s intended or inherent properties. This could happen, for instance, if the printing process does not accurately deposition building material by a printer head, or if there is insufficient feedback analysis to identify any defects in the object as it is printed. Many parts and objects may be incorrectly constructed, which can lead to the part not meeting its specifications. Extrusion-based systems can be subject to defects because they are highly dynamic at both the fluidic and system levels.
The present invention is a system and method that efficiently monitors the printing process and can identify defects in an object in real-time. The invention also provides a way to fix defects in real-time while an object is being printed. The invention also provides a method for analysing the data from the detectors and updating the tool path instructions and object model in-situ while a 3D object is being constructed.
“FIG. “FIG. 2” illustrates a system that shows a logic flow for a closed feedback system to print 3D objects by additive manufacturing, according to an embodiment of the invention. Through a user device, a user can input desired characteristics for a 3D object (three-dimensional) that must be printed as well as its inherent properties. These characteristics can be object properties required for a final object. They may include the physical geometry of the object as well as inherent properties such electrical, chemical, thermal, and/or mechanical properties. A 3D modeling program may be included on the user device. This file may contain the 3D data file 200 that specifies the property requirements for the printed object. An embodiment may include programs such as AutoCad that allow the user to create a CAD file detailing the properties of the 3D object. This may include geometrical, thermal, chemical and electrical constraints. The 3D data file 200 may be a CAD, STL, COD, or CAD file. To create the blue print necessary to print the 3D object, the user device employs conventional techniques. The 3D data files 202 are then fed to the first engine of the system 200. This engine can be a slicing or cutting engine. It will divide the 3D file 202 into segments along arbitrary planes. The slicing engine can also be used to separate the 3D data file into multiple slices along two-dimensional planes. The slicing engine then generates a set 206 of tool path instructions. This is done by using property analyzing techniques. It also includes a set 204a and 204b of slicing, material, and object property requirements. Finite element analysis may be used as the property analysis method in one embodiment of the invention.
The determined tool path instructions (206) are then used to create the object by a tool of a printer or build apparatus. The tool path instructions generated by the slicing motor are the instructions that are followed for the construction of a 3D object by a material extruder tool head. The tool path instructions 206 may be followed by the extruding head to deposit several layers of building material. The tool path instructions 206 can be modified in-situ while constructing a 3D object. This modification is based upon feedback analysis generated from data collected by one of several detection devices.
“The system 200 also includes a build apparatus, which is used to print the 3D object. The build apparatus includes a platform for three-dimensional printing. The build apparatus can communicate with the user device to receive control signals and/or tool path instructions 206. A plurality functional tool heads may be included in the build apparatus. These tool attachments can perform different functions that are required for 3D printing. Multi-axis motion mechanisms allow for the movement of the plurality of functional tool head in an arbitrary way, such as in the x, y, and z-axis. Attached to the plurality functional tool heads, the tool attachments perform a variety functions, including printing the object layer by layer, as well as supporting printing such things like cooling, heating, cooling, deburring, and milling bits.
“Tool attachments can also be oriented with multiple degrees freedom because they attach to functional tool heads with multi-axis motion mechanisms. Multi-axis motion mechanisms, such as manipulators or robotic arms, can be easily identified by a skilled person in the art. They allow attachment to a variety of tool attachments and perform different functions. An embodiment may include functional tool heads and attachments that have multiple degrees of freedom of movement, such as 5, 6, or 6.
“In another embodiment of the invention, one tool attachment may be used as an extruder, print head, or extruding channel to deposit material for the additive construction. The other attachments can also perform other functions such as cooling, heating and deburring. A controller controls the attachments to the build apparatus based on the instructions for use 206. The controller may also control each attachment independently based on which type of tool path instructions (206) are given to each attachment depending on its function.”
“In one embodiment of the invention, the attachments to the tool perform printing and corrective functions and may include a material depositionhead, laser for heating or milling bit, cooling means, heating methods and other tools with different functionalities that are used in 3D printing process.”
“In an example embodiment, one tool attachment attached to the functional tools heads may be used as a print head that extrudes the building material to print the object. The other attachments can serve as correction devices. A functional tool head that is attached to a tool attachment works as a printhead for the printing apparatus can be called ‘first functional tool head’. An?extrudinghead? is a head that extrudes layers of printable material onto the printing platform in order to create a 3D object. The extruding and first functional tool heads may be interchangeable. The extruding heads may also be controlled by a controller that extrudes material according to the tool path instructions generated by the slicing engines. To accomplish this, the user device sends 206 the evaluated tool path instructions to the controller. This further controls the extruding heads actions to extrude the layers of the build material (as described in 208)
“As stated above, one or more functional tools heads can act as corrective device. These corrective device functions can be managed by the controller, defect feedback controller, or both. The controller responsible for controlling and generating the instructions for both the extruding heads and corrective devices may be included in an embodiment of the system for printing 3D objects. Another embodiment controls the extruding heads and corrective devices using a first and second controllers, respectively.
The build apparatus uses corrective devices to correct defects in 3D objects while they are being printed by an extruder head. There may be instances when an object is printed that there are air bubbles or excessive polymer. This can cause a structural defect. It may also reduce the object’s dimensional tolerance and decrease the object’s mechanical strength. A person skilled in the arts will know that there could be many defects in printing an object. These include defects in the structure or build volume, as well as other issues. The present invention offers corrective devices for the build apparatus to fix such defects in printing the object.
The corrective devices are functional tool head attachments that follow the instructions of the defect feedback controller. Instructions are generated in response a defect is detected by one or more monitoring devices such as quality detecting device. One embodiment may have defects during the printing process, such as drooping/sagging or insufficient crystallinity. Slow solidification. Out of tolerance feature. Air bubbles, excess polymer. Delamination. Warping. Adhesion between printed layers.
Functional based corrective devices are used to correct defects. The corrective devices can perform a variety of functions in an embodiment. They may include cooling, heating and milling, deburring, and air blowing.
“The quality detecting or monitoring devices constantly monitor (210) the object and identify any printing defects while it is being printed. The quality detecting device can use detecting techniques to identify defects in objects in real-time. The detecting methods include, but are not limited to, visual imaging, IR/thermal imagery, laser techniques and audio microphones. These techniques can be used to identify the characteristics of the defects, such as type, location, corrective action and temperature. Cameras, lasers or other image detection devices are all possible, as well as audio microphones that capture unusual extrusion sounds to determine if the filament has dried properly. The quality detecting devices constantly monitor the extruding head for any errors or defects in the deposited layer. 2.”
“When defects are detected by quality detecting devices, their features are communicated to the controller (defect feedback controller), where they are analysed and processed. The defect feedback controller then generates a set of correcting instructions to correct the devices. The corrective devices’ functional tool heads may be programmed to control the corrective device according to the correcting instructions. The defect feedback controller can generate correcting instructions based on the defect and instruct corrective devices to perform the appropriate function for that defect. A catastrophic defect (i.e. If a defect is not correctable to the specifications of the user, the build can be terminated and the defect recorded in a report.
“In one embodiment of the invention, quality detecting devices may encounter situations where there are no printing errors while monitoring the process. (shown in 212). The system 200 can update the printed object model, along with the slicing parameters, tool path instructions 206, and the tool heads as indicated by 214 in system 200. The quality detecting devices might detect defects in the printing process. The system 200 generates a report detailing the errors or defects based on the defect feature. If the errors are severe (shown with 216), this may happen.
“On the flip side, if the errors aren’t catastrophic, the defect feedback controller might generate a set correcting instructions to repair the defects in the printable layers. This system 200 permits for the in-situ correction. The corrective devices and functional tool heads fix the defects in the object while it is being printed. After repairing the defects, system 200 can update the object model, along with the slicing parameters, tool path instructions, and tool heads. The system 200’s part 218 illustrates this. The system 200 can also generate a report that contains details of defects and corrective instructions if the object has been printed. The optimized slicing parameters can be saved for the next build.
“In an embodiment, the identified defect and the build parameters (extrudate width, layer thickness, etc.) are combined. The slicing feedback controller analyzes the data in-situ as it is being printed. Analyses are performed in accordance with the intended object geometry and property (e.g., mechanical, thermal, chemical or electrical). The slicing feedback controller then generates a set slicing directions based on the analysis. To reduce future defects and meet the object requirements, the slicing instruction adjusts the tool path instructions206 for all subsequent layers.
“In one embodiment of the invention, a single controller can perform the functions of both the defect feedback controller (controlling the extruding head) and the slicing feedback control controller (controlling the corrective devices).”
The system can monitor the printing process in real-time and implement the quality detecting device to detect defects. It will also generate correcting instructions and adjust the tool paths for the subsequent layers. This correction takes place in-situ during the 3D object’s printing. The present invention allows for the monitoring and identification of defects in 3D objects using a quality detecting device. This is done while the object is being printed. Corrective devices are used to correct the errors.
“The build device allows for independent and automated control over the functional tool heads with extruding heads and corrective devices, based on feedback analysis from quality detecting devices or the defect feedback controller.”
“In one embodiment of the invention, the build apparatus can contain a single functional head with attachment points for attaching a plurality tools to perform different functions.” The controller will send instructions to the functional tool head of the build apparatus and tell it to select the desired tool.
“Each functional tool head is a working tool of the build apparatus and they are independent of each other. They are driven automatically based on instructions from the defect feedback controller and the user device.
The corrective devices fix the defects in the printing process. However, the slicing Feedback Controller also analyses the information and builds parameters to determine the object geometry and properties. mechanical, chemical, thermal, electrical, etc.). To generate the correct instructions for the slicing machine, the in-situ object properties and geometry are compared to the input object requirements. These instructions alter the slicing parameters as well as the resulting toolpath instructions 206 to reduce future defects and ensure that object requirements are met.
The present invention is a method of generating optimal tool path directions 206 for building 3D objects. The present invention also provides a system for monitoring and correcting defects in 3D objects while they are being printed. It implements a variety of quality detecting and corrective devices. The present invention also provides a method to modify the toolpath instructions 206 in-situ while constructing a 3D object. This is based on feedback analysis from quality detection devices.
The extruder head can be fed with a material to be printed in additive manufacturing. An embodiment of the building material could be an amorphous, semi-crystalline, or a metallic material.
The controller controls the movement of the functional head in an embodiment of the invention. The controller receives the tool path instructions and controls the movement of the functional head. Cartesian or non-Cartesian mechanisms can control the movement of the functional head. Cartesian movement allows the functional heads to move in the X, Z, and Y-axes. Axial movement is not allowed. Non-Cartesian movement allows the functional heads to freely move in any axis.
“The system 200 components will be described in detail in the following figures.”
“FIG. “FIG. FIG. FIG. 3 shows a block diagram that illustrates components of the system 200. These components help to cut a 3D file into layers printable and then deposit the layers. A user can input the desired characteristics of a 3D object in a 3D file to print it. The invention determines the optimal tool path instructions for the object and its slicing parameters. The system 200 can use detecting and analyzing instruments to determine the optimal tool path instructions.
The slicing parameters, material properties 204a and the object property requirements (204b) may determine the tool path instructions206. To print layers of building material on a 3D platform, the tool path instructions 206 can be used by an extruder tool head. The tool path instructions 206 can be modified in-situ to construct a 3D object using the analysis provided by the slicing feedback control.
The present invention could include a slicing machine 300 that takes into account the slicing parameters, material properties 204a, and object property requirements (204b) for separating a 3D file 202 of a desired object. The slicing machine 300 separates the 3D file 202 into multiple segments that are aligned along an arbitrary plane. The slicing engine 300 can also be used to slice the 3D file 202 into a plurality of layers for printing. The tool path instructions 206 are then generated based upon the discretization performed by the slicing engines 300.
“The extruding attachment 306 is connected to the functional tool heads, 304 and controlled by a controller 312. The tool path instructions 206 are generated by the controller 302, which controls the functional tools heads 304 and tells them how to extrude the building material. The extrusion takes place using the extruding heads 306; therefore, the functional tools head activates its extrudinghead or mounts the attachment and instructs it follow the tool path instructions to deposit the printed layers of building material. The extruding heads 306 then deposits a number of layers under the control and following the instructions 206.
The functional tool heads 304, which are automatic working devices of the build device, have multiple degrees of freedom of movement and can be used to print 3D objects. They also support in printing them. The functional tool heads 304 can have multiple degrees of freedom, for example, 5, 6, or 6.
The extruding head may be fed with a material from which the 3D object can be built. An embodiment of the building material could be an amorphous, semi-crystalline, metallic, ceramic, carbon, or any other reinforced material.
“FIG. “FIG. FIG. FIG. 2 shows that, in addition to the extruding heads, other functional tool head can be used as corrective devices during the printing process. Corrective devices are the automatic working devices that assist in printing an object. They can correct defects in real-time. One or more defects can be created during the extruding process. One embodiment may have a variety of defects, including but not limited to: drooping/sagging; insufficient crystallinity; slow solidification; out of tolerance feature; excess polymer; delamination; overhangs; warping; adhesion between printed layers of an object. These can all lead to insufficient mechanical, chemical or thermal properties.
“In addition, the system 200 could include one or more monitoring devices such as quality-detecting devices 400. The 400-watt quality detecting device may monitor the printing process continuously and detect any defects that are forming in the object. The quality detecting device 400 may monitor the printing process in real-time. It can use x-rays, infrared or visual imaging to determine the dimensionality and contour of the object; or audio microphones to detect the dryness of the filament. Or defect sensing, which includes identification of the type and location of defects. Quality detecting devices 400 measure critical features of an object in order to verify that each feature falls within the acceptable tolerance set by the user.
“Quality detecting devices 400 can make use of detecting methods for monitoring the building process in real-time and identifying defects in the object. The detecting techniques include, but are not limited to, visual imaging, IR/thermal imagery, laser techniques and audio microphones to identify the characteristics of the defects, such as type, location, temperature, correction action and the like.
The quality detecting devices 400 keep an eye on the 3D object as it is being printed using the extruding heads. They also monitor the process in real-time and maintain a constant check on the printing process. The quality detecting devices 400 can detect defects in objects by using various techniques. The quality detecting devices 400 can then store the data captured in a data storage unit. This data stores the information that defines the defects such as their location, type, contour, dimensions, and critical features. The present invention allows for the recording and logging real-time events such as defects, corrections and the location of each defect within 3D space. It also records modifications to the object model or slicing parameters.
“The detected data can be transmitted to a controller such as a defect feedback control 402, which implements analyzing tools that predict correcting instructions 404. Correcting instructions describe the steps to be taken to correct defects and predict the object’s properties based on the type of defect detected by the quality detecting device 400. A defect feedback controller 402 could be an example of a correction module. It analyzes data collected from quality detecting devices 400 to generate feedback (including correcting instruction 404) depending on the characteristics of the defects. A slicing feedback control 408 analyzes the information about defects and build parameters to determine in-situ object geometry. mechanical, chemical, thermal, electrical, etc.). Based on the deficient data, the in-situ object properties and geometry are compared to the input object requirements. The appropriate slicing instruction 410 is generated for the slicing machine 300. To reduce future defects and meet object requirements, these slicing directions 410 modify the tool path instructions (206).
“In one embodiment, the system 200 to print a 3D object consists of a single controller that controls the extruding heads and corrective devices and generates the instructions.”
“The defect feedback control 402 can determine the properties of the object to be printed and the correcting instruction 404 based on the defects found and the object’s desired strength. The defect feedback controller 402 can also instruct corrective devices to perform the corresponding functions according to the correcting instructions. The controller 302 may receive the correcting instructions 404. This further controls the functional tools heads 304. The correcting instructions 404 are received by the functional tool heads. They instruct the tool head attachments (corrective devices 406) to be used. The corrective devices 406 then perform the functions required by the correcting instructions.
The corrective devices 406 may be attached to the functional tools 304 to perform a function to correct a corresponding defect. This function could include cooling, heating and milling the object, or deburring the object. The correction devices 406 can perform the function necessary to correct a specific defect.
For example, if quality detecting devices 400 detect that the printed layers are not adhering to each other and this results in an inaccurate geometry, reduced thermal conductivity, reduced mechanical strength, or similar, the defect feedback controller 402. determines that heating the deposited material is necessary for proper adhesion. The defect feedback controller 402 can determine whether there is heating. As the correcting instructions 404, the defect feedback controller 402 may determine?heating? and direct a corresponding corrective tool (406) to heat the deposited layers in order to ensure adhesion. The slicing feedback control 408 may alter the slicing directions 410 to address the identified defect. This will allow the tool path instructions (206) to be modified in order reduce the likelihood of future defects and meet object requirements. Modified slicing instructions could include decreasing the layer height, increasing material feed rate and/or increasing extrudate width.
The system 200 monitors the printing process in real-time and detects defects by using quality detecting devices 400. The controller 302 also provides an independent and automated control of corrective devices, based upon feedback analysis. This allows for the correction of defects in the object, and modification of appropriate tool path instructions (206), in real-time. This results in a 3D object that is free from defects.
“In one embodiment of the invention, the build apparatus may have a single functional head 304 with attachment points for attaching a plurality tools performing different functions.” The controller can send instructions to the functional tool head 304 to select the tool.
“Another embodiment of the invention allows the functional tool head to be attached to multiple tool attachments, where the controller controls the movement of each tool attachment. Each tool attachment contains an attachment point that provides an attachment means to the functional tool heads 304 for different functions in the 3D printing process. Each of the attachments, or arms, are the tools that make up the build apparatus. They are independent and can be driven automatically based on instructions from the controller 302 or the defect feedback controller 402.
The printing system can also provide a build report. A build report can be generated by the user device after the printing process is completed. A build engine on the device might generate a visual build report that displays each uncorrected and corrected defect in 3D space. This report will include information about the type of defect and its location within the object. An analyzing module on the device uses the information contained in the build report to determine the material properties of final objects based upon the type, number and location of uncorrected and corrected defects. An analyzing module can use finite element analysis or other techniques.
The build report compares the final object’s material properties to the user’s specifications. It also identifies any properties that are not in the specifications by using analyzing techniques. A user may use the information in the build reports to help decide whether to keep or throw away the final object. This is based on the properties of the final printed object as well as the details of the uncorrected and corrected defects. This is an important step in determining the value or suitability for the intended purpose of the final object.
Further, the build report can be used to resolve mechanical, thermal, and uncorrected defects in the built object. It may then be reprinted with the same building parameters and constraints. The build report can be used to optimize the tool path instructions206 for printing identical or similar objects. It also helps in determining the value of the final printed object. A finite element analysis may be used to determine the material properties of final objects and to decide whether or not to keep them.
“FIG. “FIG. Column 502 lists the possible defects that could occur during 3D printing. A defect could occur during printing, such as excess polymer being deposited by the first robot manipulator. Visual Imaging, Laser (504) may detect this type of defect. The defect feedback controller 402 will then determine the corrective actions (correcting instructions), which may include deburring or radiative heating (506). The appropriate functional tool heads 304 are then notified of the course of action. They can perform either deburring or radiative heating or tamping. The defect feedback controller 402. provides instructions to the appropriate functional tool heads 304. The functional tool heads 304 perform the function by moving in the x, y, and z axes. For correcting defects in 3D, the functional tool head 304 must be moved. The movement of functional toolhead 304 in an embodiment of the invention can be done in either a Cartesian mechanism, where the tool heads are moved in the X,Y, and Z directions, or through a non-cartesian method, where the functional tool heads can freely move in three-dimensional space.
“The slicing feedback control 408 can also generate slicing directions 410 to stop excess polymer being deposited in the subsequent layers. The slicing instructions could include increasing the layer height, decreasing material feed rate, or decreasing the extrudate thickness. This allows for a variety quality detecting techniques to detect defects during printing. The feedback controllers 402 or 408 may determine the correcting and slicing instruction 404.
“FIG. “FIG. 6” illustrates an example illustration in which functional tool heads 304 are attached at a variety of tool head attachments 604 that are used in additive manufacturing. FIG. FIG. 6 shows that each functional toolhead 304 may include a tool attachment point 602. A tool attaching point 602 can be used to attach a tool attachment 604 to a functional tool head 304. This may be used to fix a toolhead attachment 604 that is performing a particular function. Functional tool heads 304 allow the printing process to be performed in an automated manner. The functional tool heads 304 can be equipped with tool attachment 604 which performs a specific function. These attachments are attached to the tool attaching points 602 of functional tool head 304. The functional toolhead 304 might also pick up various fixtures. These fixtures are attached via the tool attaching points 602 to the functional head 304.
If a functional toolhead 304 is asked to cool, it may grab a fixture or attachment 604 and attach the specific tool attachment 604 via tool attaching point 602. If the functional toolhead 304 is asked to take a thermal image and it drops the cooling toolhead, it may pick up a fixture or attachment 604 and attach the specific tool attachment 604 via tool attaching point 602. The functionality of the functional toolhead 304 can be interchanged depending on the printing process.
“In another embodiment, functional tool heads 304 can perform dedicated functions such as heating, cooling, depositing build material and milling, deburring, laser heat, blowing or blowing air. Each functional tool head 304 is attached to the corresponding tool heads 604 via the tool attachment point 602.
“FIG. “FIG. 7” illustrates a flowchart that shows a method for additive manufacturing, which allows the printing of a 3D object. This process monitors the printing process and identifies and corrects any defects. A user can input a 3D file 202 via a device using step 702, where the 3D file defines the characteristics and dimensions of a 3D object. The embodiment of the invention may include a computer or other computing device. It may also include software for 3-D modeling, such as AutoCad, and similar programs. A third embodiment may contain a 3D data file that includes a CAD, STL, or COD file. Another embodiment may contain characteristics such as the object’s structural geometry, inherent material properties and mechanical, electrical, chemical and thermal properties. Another embodiment of additive manufacturing is extrusion-based printing or continuous fiber-based deposition processes. This includes fused deposition modeling, fused fil fabrication, and the like. Other methods include droplet-based jetting and the like.
“After receiving the 3D files 202, a first engine such as a slicer engine 300, separates the 3D files 202 into segments that run along arbitrary planes at step 704. The slicing engines 300 can also be used to separate the 3D file 202 into multiple slices along two-dimensional planes. After slicing the file 202 at step 706, a set 206 of tool path instructions is created using the slicing engines 300. These instructions are based on a set 204a and 204b of object property requirements and slicing parameters. To reduce future defects and meet object requirements, the tool path instructions 206 can also be adjusted in-situ using the slicing feedback control.
The build apparatus could include a number of functional tool heads, 304 and a variety of attachments that allow for multiple degrees of freedom of movement to print a 3D object. The functional tool heads 304 may have multiple attachments, such as 5, 6, or more degrees of freedom. Based on feedback analysis, the functional tool heads 304 work independently and simultaneously with each other. One or more attachments to the tool heads 304 may also be used as extruders, print heads, or deposition heads for depositing layers build material on the printer platform. Deposition head attachments may also be known as extruding heads 306 and can be controlled by a controller. For receiving tool path instructions, the controller 302 is still in communication with user device. At step 508, the controller might instruct the extruder head 306 to follow instructions 206 and deposit printable layers of a material to create the 3D object.
The controller 302 controls the movement of the functional head 304 in an embodiment. After receiving the tool path instruction (206) required to print the 3D objects, the controller 302 controls the movement and direction of the functional heads. Cartesian or non-Cartesian mechanisms can control the movement of the functional head 304. Cartesian movement allows the functional heads 304 to be moved along the X, Z, and Y-axes. Axial movement is not allowed. Non-Cartesian movement allows the functional heads 304 to freely move in any direction.
The extruding head 306 may be deposited layers of build material onto the printing platform. However, the object may have one or more defects that could further cause faults in geometry and inherent properties such as low mechanical strength. An embodiment may have drooping/sagging and insufficient crystallinity. Slow solidification, out-of-tolerance feature, air bubbles and excess polymer. Warping and adhesion can also occur between the printed layers.
The system includes one or more monitoring devices such as quality detecting device 400 to monitor the printing process continuously. Quality detecting devices 400 can use detecting techniques to detect defects in 3D objects being printed. These techniques can include visual imaging, IR/thermal, laser techniques, audio mics, and other techniques to detect the characteristics of defects, such as type, temperature, correction action, location, and so on. The quality detecting devices 400 can monitor the printing process continuously and detect defects that are forming in the object at step 710. Thermal sensors, cameras, lasers or any other image detection device, infrared devices to inspect the geometry of the object, microphones to record abnormal extrusion sounds to determine if the filament has dried properly, and similar devices are all part of the quality detecting devices 400.
“The present invention further provides a method for correcting defects in real-time while an object is being printed. One or more functional tool heads 304 can be used as corrective devices 406 to fix defects detected by quality detecting devices 400. One or more corrective device 406 is a tool head that performs one or more functions to correct one or several defects. The functions can include cooling, heating or milling the object, or deburring it.
“As soon the quality detecting device 400 detects defects and their features, such a location and type of defect location, they can store the defects data into a data storage module. The data defines the features such as location, type, contour, critical feature measurements, dimensions, and dimensionality of the built object. The present invention allows for the recording and logging real-time events such as corrections, defects, and location in 3D space.
“The data from the quality-detecting devices 400 can be fed to a controller such as a defect feedback control 402. The feedback controller 402 analyzes the data to generate correcting instructions 404. These instructions should be followed to fix the defects. An embodiment of this invention uses finite element analysis to predict the object’s properties based on the types of defects identified by quality detecting devices 400. The defect feedback controller 400 can be used to generate feedback (correcting instruction 404) depending on the characteristics of the defects.
After generating the correcting directions 404, the defect feedback control 400 may control corrective devices 406. It will instruct them to perform the corresponding functions based upon the feedback generated, including the correcting instruction 404. The corrective devices 406 are activated at 712 and can be used independently to correct the 3D objects’ defects during the printing process.
“At step 714, taking into account the defective data from the quality-detecting devices 400, controllers, such as a Slicing Feedback Controller 408, may modify the implemented cutting instructions 410 for slicing engines 300 to further separate the 3D data file. 202. To reduce future defects and to ensure that object requirements are met, the modified slicing directions 410 modify the tool path instruction 206.
After the printing and correcting processes are completed, the user device may generate a build report (step 716), which is based on the printing process and any corrections made. The feedback from the build volume may allow the user device to generate a visual build report that displays in 3D space all features and any uncorrected defects. An analyzing module on the device may use the information contained in the build report to determine the material properties of final objects based on type, location, and number of uncorrected defects. The report compares the final object’s actual material properties with the user’s specifications, and identifies any properties which are not in line with these specifications.
“In addition, the build report can help the user decide whether to keep or throw away the final object. It will include information about the expected inherent properties as well as the details of the uncorrected and corrected defects. This is an important step in determining the value of the final object. The build report can also be used to resolve mechanical, thermal, and uncorrected problems of the built object. It may then be reprinted with the same building parameters and constraints. The build report can be used to optimize the tool path instructions 206 for printing identical or similar objects. It also helps the user determine the value of the final printed object.
The present invention is a system and method for three-dimensional printing. It monitors the printing process in real time to identify any defects in the object. The present invention also allows for in-situ corrections of defects during printing by an automated and independent control of functional tool head based on feedback analysis.
“Following example may help you understand the invention clearly.”
“In one embodiment of the present invention, a 3D printer machine includes two independent controlled multi-axis functional tools heads. These functional tool heads could be robotic arms. Robotic arm X is composed of an extruder, while robotic arm Y acts as a real time correction device.
“Robotic arm X can be controlled by the toolpath instructions 206 generated in the CAD file.”
“Robotic arm Z can use a variety of interchangeable fixtures in order to correct part manufacturing defects. Considering, ?B? Consider?B?? A multi-axis system that includes D devices is used to detect defects in real time during production. D devices are quality-detecting devices. Image processing software determines the type, number, and location of defects. This information is passed to the robotic arm’s control software (feedback controller), which determines the correct course of action. Some defects cannot be corrected by robotic arm, but they are still stored in the data storage module. This information is used to create a final build report.
“Further Robotic arm Y picks the correct fixture with?A?” To correct the defect, functionality is provided. If the deposition site has not been affected, robotic arm X may continue extruding material. Otherwise, robotic arm X will wait until robotic arm Y has completed correcting the defect. This information is used to modify the printed object model and slicing parameter. The subsequent tool path instructions for robotic armX are then modified. Robotic armY performs the same operation to correct any defects during the entire build process.
The build report, which displays every defect and its location in the part, is generated after the build process has been completed. Based on the location, type, and number of uncorrected defects, this information can be used to predict the material properties for the final part.
“In an embodiment the functionality?A?” The functionality can include cooling, heating, or milling/deburring. The defect?B? in an embodiment is The defect?B? in an embodiment can include drooping/sagging or insufficient crystallinity, slow liquidification, out-of-tolerance feature, and other such things. The defect?C? Air bubbles, excess polymer or delamination, warping, adhesion among printed layers of an object, and the like.
“In an embodiment, a quality detecting device?D?” It can include visual imaging, IR/thermal and laser techniques.
Summary for “Method for monitoring additive manufacturing processes for detection and correction of in-situ defects”
The additive manufacturing process, also known as three-dimensional printing of 3D objects, is well-known. Numerous methodologies have been described in prior art, the most common including solid-laser-sintering (?SLS? Stereolithography (?SLA?) is another method. Stereolithography (?SLA?) The deposition of thermoplastic material is part of extrusion-based 3D printing. Extrusion-based 3D printing is most commonly used today for prototyping. It uses materials like ABS (acrylonitrilebutadiene styrene), and PLA (polylactic acids). The technology has advanced to the point that 3D printing can now use higher-end engineering semicrystalline and amorphous plastics as well as metals, ceramics, and materials with better mechanical, chemical and electrical properties. Examples of semi-crystalline polymers include polyetheretherketone (PEEK), polyetherketoneketone (PEKK), etc. Polyphenylsulphone, polyetherimide, and others are examples of amorphous engineering plasticmers.
“Prior art in extrusion-based 3D printing is about extruding filament through an extruder, depositing the extrudate onto a platform and forming a 3D object one layer at a. Time. There is no feedback regarding the build process or the quality of deposition. Defects in 3D object printing can lead to errors in its geometry, i.e. Dimensions or contours) and deficiencies in desired properties (e.g. ”
These defects, errors or characteristics, which are not in accordance with the intended design, such as deviations in filament diameter, feed rate, and nozzle orifice, can result in an inaccurate volume of extrudate deposited; inaccuracy of the print head to follow desired tool path, leading to out of tolerance features; deviations in heating or cooling the material to deposit it, causing defects such as drooping/sagging or reduced crystallinity; delamination; warping or overhangs between the object or the plate These defects, if not corrected can lead to flaws in the printed object such as inadequate mechanical, chemical or thermal properties.
FIG. 1. The software cuts a 3D object file (100), into a number layers (102) by using slicing parameters like filament diameter, nozzle size, layer thickness, fill rate, speed, etc. Each layer receives tool path instructions (104) that are sent to the 3D printer. The 3D printer prints each layer without any way to monitor, correct or detect errors. The printing ceases (108) when the layer printing is complete (106). If not, the method loops back and prints the next layer using the extruder (104)
“The prior art does not provide a quantitative or qualitative report that could inform a 3D printer user about the structure and features of the printed object. It may also guide them in deciding whether to keep the object or throw it away. These reports are also not available to assist in improving the printing process for three-dimensional objects.
There is a need for three-dimensional printing methods that monitor and identify defects in 3D objects while they are being printed. Further, the object can be corrected in-situ as it is printed. A closed-loop slicing system that updates the object model and slicing parameters in-situ based on object geometry and defect data is also needed. Three-dimensional printing has the potential to create a report that displays geometry as well as the features of uncorrected and corrected defects in 3D printing processes. This will allow for improvements in printing.
The present invention improves additive manufacturing by identifying and monitoring defects while a 3D object is being printed. In-situ corrections of defects are made based on quality control feedback during printing. Finally, slicing parameters and objects models are updated based upon the correction. Based on the object property requirements and slicing parameters, a 3D object layer or segment is cut. The tool path instructions for segment and layer are generated, then fed to the 3D printer for printing. The quality of the printed segment, layer or build feature (i.e. Through-hole, contoured section and overhang are all possible. are analyzed for any defects. If the defect can be corrected, a tool path is created for the tool with capabilities such as drilling, milling, heating, extrusion, etc. Attached to a head that is capable of following multi-dimensional paths,
“Next, the object modeling and slicing parameters will be updated based upon analysis of previously printed segments, layers, or build features, as well as corrected defects. The segment, layer or build feature are analyzed and a qualitative and quantitative report is generated. The report logs temperature, speed, material use, and imaging data. After the object has been printed, a final report with property analysis is generated. Final report determines whether the object has the intended properties. Based on in-situ parameter adjustments made during build, it also records modified instructions for the next build.
The present invention has the objective of providing a system that monitors, identifies and corrects defects. It also updates tool path instructions and the object model in-situ during 3D object formation. This effectively adds a closed loop feedback mechanism for part quality.
The present invention provides a method for monitoring, identifying, and correcting defects and updating tool path instructions as well as object model in-situ while 3D objects are being printed. This effectively adds a closed loop feedback mechanism to improve part quality.
“The present invention aims to provide multiple functional tool heads with multi-axes motion mechanism. They can be independently controlled and automatically controlled to perform one or several functions. This is done based on feedback analysis to correct any defects.
“Another objective is the present invention to provide a means of logging real-time events such as identified defects, critical feature measurements and dimensionality.
“Another objective is the invention to generate a report listing all defects in the printed 3D object. The build report can then be used for predicting the properties of the final built part such as mechanical strength and electrical conductivity. To minimize defects in future runs, the build report can be used to optimize build parameters and the tool path.
The following description of embodiments of invention provides a detailed understanding of the invention. A skilled person in the art will know that embodiments of invention can be used with or without these details. Other well-known methods, procedures, and components are not described in detail to avoid confusing aspects of the embodiments.
“It will also be apparent that the invention does not limit itself to these embodiments. Many modifications, variations, substitutions, and equivalents are possible for those skilled in art. They do not have to depart from the spirit or scope of the invention.
The present invention provides an additive manufacturing method to print or build a 3D object/part. It includes, but is not limited, to extrusion-based, fused filament fabrication and droplet based printing methods. The invention also provides a method and system to monitor and correct defects in objects while they are being printed using additive manufacturing. This allows for the production of a 3D object that meets all specifications. ”
Incorrect or incorrectly built parts can happen during additive manufacturing and three-dimensional printing processes. These printing processes can lead to defects in the structural geometry and other problems that may affect the part’s intended or inherent properties. This could happen, for instance, if the printing process does not accurately deposition building material by a printer head, or if there is insufficient feedback analysis to identify any defects in the object as it is printed. Many parts and objects may be incorrectly constructed, which can lead to the part not meeting its specifications. Extrusion-based systems can be subject to defects because they are highly dynamic at both the fluidic and system levels.
The present invention is a system and method that efficiently monitors the printing process and can identify defects in an object in real-time. The invention also provides a way to fix defects in real-time while an object is being printed. The invention also provides a method for analysing the data from the detectors and updating the tool path instructions and object model in-situ while a 3D object is being constructed.
“FIG. “FIG. 2” illustrates a system that shows a logic flow for a closed feedback system to print 3D objects by additive manufacturing, according to an embodiment of the invention. Through a user device, a user can input desired characteristics for a 3D object (three-dimensional) that must be printed as well as its inherent properties. These characteristics can be object properties required for a final object. They may include the physical geometry of the object as well as inherent properties such electrical, chemical, thermal, and/or mechanical properties. A 3D modeling program may be included on the user device. This file may contain the 3D data file 200 that specifies the property requirements for the printed object. An embodiment may include programs such as AutoCad that allow the user to create a CAD file detailing the properties of the 3D object. This may include geometrical, thermal, chemical and electrical constraints. The 3D data file 200 may be a CAD, STL, COD, or CAD file. To create the blue print necessary to print the 3D object, the user device employs conventional techniques. The 3D data files 202 are then fed to the first engine of the system 200. This engine can be a slicing or cutting engine. It will divide the 3D file 202 into segments along arbitrary planes. The slicing engine can also be used to separate the 3D data file into multiple slices along two-dimensional planes. The slicing engine then generates a set 206 of tool path instructions. This is done by using property analyzing techniques. It also includes a set 204a and 204b of slicing, material, and object property requirements. Finite element analysis may be used as the property analysis method in one embodiment of the invention.
The determined tool path instructions (206) are then used to create the object by a tool of a printer or build apparatus. The tool path instructions generated by the slicing motor are the instructions that are followed for the construction of a 3D object by a material extruder tool head. The tool path instructions 206 may be followed by the extruding head to deposit several layers of building material. The tool path instructions 206 can be modified in-situ while constructing a 3D object. This modification is based upon feedback analysis generated from data collected by one of several detection devices.
“The system 200 also includes a build apparatus, which is used to print the 3D object. The build apparatus includes a platform for three-dimensional printing. The build apparatus can communicate with the user device to receive control signals and/or tool path instructions 206. A plurality functional tool heads may be included in the build apparatus. These tool attachments can perform different functions that are required for 3D printing. Multi-axis motion mechanisms allow for the movement of the plurality of functional tool head in an arbitrary way, such as in the x, y, and z-axis. Attached to the plurality functional tool heads, the tool attachments perform a variety functions, including printing the object layer by layer, as well as supporting printing such things like cooling, heating, cooling, deburring, and milling bits.
“Tool attachments can also be oriented with multiple degrees freedom because they attach to functional tool heads with multi-axis motion mechanisms. Multi-axis motion mechanisms, such as manipulators or robotic arms, can be easily identified by a skilled person in the art. They allow attachment to a variety of tool attachments and perform different functions. An embodiment may include functional tool heads and attachments that have multiple degrees of freedom of movement, such as 5, 6, or 6.
“In another embodiment of the invention, one tool attachment may be used as an extruder, print head, or extruding channel to deposit material for the additive construction. The other attachments can also perform other functions such as cooling, heating and deburring. A controller controls the attachments to the build apparatus based on the instructions for use 206. The controller may also control each attachment independently based on which type of tool path instructions (206) are given to each attachment depending on its function.”
“In one embodiment of the invention, the attachments to the tool perform printing and corrective functions and may include a material depositionhead, laser for heating or milling bit, cooling means, heating methods and other tools with different functionalities that are used in 3D printing process.”
“In an example embodiment, one tool attachment attached to the functional tools heads may be used as a print head that extrudes the building material to print the object. The other attachments can serve as correction devices. A functional tool head that is attached to a tool attachment works as a printhead for the printing apparatus can be called ‘first functional tool head’. An?extrudinghead? is a head that extrudes layers of printable material onto the printing platform in order to create a 3D object. The extruding and first functional tool heads may be interchangeable. The extruding heads may also be controlled by a controller that extrudes material according to the tool path instructions generated by the slicing engines. To accomplish this, the user device sends 206 the evaluated tool path instructions to the controller. This further controls the extruding heads actions to extrude the layers of the build material (as described in 208)
“As stated above, one or more functional tools heads can act as corrective device. These corrective device functions can be managed by the controller, defect feedback controller, or both. The controller responsible for controlling and generating the instructions for both the extruding heads and corrective devices may be included in an embodiment of the system for printing 3D objects. Another embodiment controls the extruding heads and corrective devices using a first and second controllers, respectively.
The build apparatus uses corrective devices to correct defects in 3D objects while they are being printed by an extruder head. There may be instances when an object is printed that there are air bubbles or excessive polymer. This can cause a structural defect. It may also reduce the object’s dimensional tolerance and decrease the object’s mechanical strength. A person skilled in the arts will know that there could be many defects in printing an object. These include defects in the structure or build volume, as well as other issues. The present invention offers corrective devices for the build apparatus to fix such defects in printing the object.
The corrective devices are functional tool head attachments that follow the instructions of the defect feedback controller. Instructions are generated in response a defect is detected by one or more monitoring devices such as quality detecting device. One embodiment may have defects during the printing process, such as drooping/sagging or insufficient crystallinity. Slow solidification. Out of tolerance feature. Air bubbles, excess polymer. Delamination. Warping. Adhesion between printed layers.
Functional based corrective devices are used to correct defects. The corrective devices can perform a variety of functions in an embodiment. They may include cooling, heating and milling, deburring, and air blowing.
“The quality detecting or monitoring devices constantly monitor (210) the object and identify any printing defects while it is being printed. The quality detecting device can use detecting techniques to identify defects in objects in real-time. The detecting methods include, but are not limited to, visual imaging, IR/thermal imagery, laser techniques and audio microphones. These techniques can be used to identify the characteristics of the defects, such as type, location, corrective action and temperature. Cameras, lasers or other image detection devices are all possible, as well as audio microphones that capture unusual extrusion sounds to determine if the filament has dried properly. The quality detecting devices constantly monitor the extruding head for any errors or defects in the deposited layer. 2.”
“When defects are detected by quality detecting devices, their features are communicated to the controller (defect feedback controller), where they are analysed and processed. The defect feedback controller then generates a set of correcting instructions to correct the devices. The corrective devices’ functional tool heads may be programmed to control the corrective device according to the correcting instructions. The defect feedback controller can generate correcting instructions based on the defect and instruct corrective devices to perform the appropriate function for that defect. A catastrophic defect (i.e. If a defect is not correctable to the specifications of the user, the build can be terminated and the defect recorded in a report.
“In one embodiment of the invention, quality detecting devices may encounter situations where there are no printing errors while monitoring the process. (shown in 212). The system 200 can update the printed object model, along with the slicing parameters, tool path instructions 206, and the tool heads as indicated by 214 in system 200. The quality detecting devices might detect defects in the printing process. The system 200 generates a report detailing the errors or defects based on the defect feature. If the errors are severe (shown with 216), this may happen.
“On the flip side, if the errors aren’t catastrophic, the defect feedback controller might generate a set correcting instructions to repair the defects in the printable layers. This system 200 permits for the in-situ correction. The corrective devices and functional tool heads fix the defects in the object while it is being printed. After repairing the defects, system 200 can update the object model, along with the slicing parameters, tool path instructions, and tool heads. The system 200’s part 218 illustrates this. The system 200 can also generate a report that contains details of defects and corrective instructions if the object has been printed. The optimized slicing parameters can be saved for the next build.
“In an embodiment, the identified defect and the build parameters (extrudate width, layer thickness, etc.) are combined. The slicing feedback controller analyzes the data in-situ as it is being printed. Analyses are performed in accordance with the intended object geometry and property (e.g., mechanical, thermal, chemical or electrical). The slicing feedback controller then generates a set slicing directions based on the analysis. To reduce future defects and meet the object requirements, the slicing instruction adjusts the tool path instructions206 for all subsequent layers.
“In one embodiment of the invention, a single controller can perform the functions of both the defect feedback controller (controlling the extruding head) and the slicing feedback control controller (controlling the corrective devices).”
The system can monitor the printing process in real-time and implement the quality detecting device to detect defects. It will also generate correcting instructions and adjust the tool paths for the subsequent layers. This correction takes place in-situ during the 3D object’s printing. The present invention allows for the monitoring and identification of defects in 3D objects using a quality detecting device. This is done while the object is being printed. Corrective devices are used to correct the errors.
“The build device allows for independent and automated control over the functional tool heads with extruding heads and corrective devices, based on feedback analysis from quality detecting devices or the defect feedback controller.”
“In one embodiment of the invention, the build apparatus can contain a single functional head with attachment points for attaching a plurality tools to perform different functions.” The controller will send instructions to the functional tool head of the build apparatus and tell it to select the desired tool.
“Each functional tool head is a working tool of the build apparatus and they are independent of each other. They are driven automatically based on instructions from the defect feedback controller and the user device.
The corrective devices fix the defects in the printing process. However, the slicing Feedback Controller also analyses the information and builds parameters to determine the object geometry and properties. mechanical, chemical, thermal, electrical, etc.). To generate the correct instructions for the slicing machine, the in-situ object properties and geometry are compared to the input object requirements. These instructions alter the slicing parameters as well as the resulting toolpath instructions 206 to reduce future defects and ensure that object requirements are met.
The present invention is a method of generating optimal tool path directions 206 for building 3D objects. The present invention also provides a system for monitoring and correcting defects in 3D objects while they are being printed. It implements a variety of quality detecting and corrective devices. The present invention also provides a method to modify the toolpath instructions 206 in-situ while constructing a 3D object. This is based on feedback analysis from quality detection devices.
The extruder head can be fed with a material to be printed in additive manufacturing. An embodiment of the building material could be an amorphous, semi-crystalline, or a metallic material.
The controller controls the movement of the functional head in an embodiment of the invention. The controller receives the tool path instructions and controls the movement of the functional head. Cartesian or non-Cartesian mechanisms can control the movement of the functional head. Cartesian movement allows the functional heads to move in the X, Z, and Y-axes. Axial movement is not allowed. Non-Cartesian movement allows the functional heads to freely move in any axis.
“The system 200 components will be described in detail in the following figures.”
“FIG. “FIG. FIG. FIG. 3 shows a block diagram that illustrates components of the system 200. These components help to cut a 3D file into layers printable and then deposit the layers. A user can input the desired characteristics of a 3D object in a 3D file to print it. The invention determines the optimal tool path instructions for the object and its slicing parameters. The system 200 can use detecting and analyzing instruments to determine the optimal tool path instructions.
The slicing parameters, material properties 204a and the object property requirements (204b) may determine the tool path instructions206. To print layers of building material on a 3D platform, the tool path instructions 206 can be used by an extruder tool head. The tool path instructions 206 can be modified in-situ to construct a 3D object using the analysis provided by the slicing feedback control.
The present invention could include a slicing machine 300 that takes into account the slicing parameters, material properties 204a, and object property requirements (204b) for separating a 3D file 202 of a desired object. The slicing machine 300 separates the 3D file 202 into multiple segments that are aligned along an arbitrary plane. The slicing engine 300 can also be used to slice the 3D file 202 into a plurality of layers for printing. The tool path instructions 206 are then generated based upon the discretization performed by the slicing engines 300.
“The extruding attachment 306 is connected to the functional tool heads, 304 and controlled by a controller 312. The tool path instructions 206 are generated by the controller 302, which controls the functional tools heads 304 and tells them how to extrude the building material. The extrusion takes place using the extruding heads 306; therefore, the functional tools head activates its extrudinghead or mounts the attachment and instructs it follow the tool path instructions to deposit the printed layers of building material. The extruding heads 306 then deposits a number of layers under the control and following the instructions 206.
The functional tool heads 304, which are automatic working devices of the build device, have multiple degrees of freedom of movement and can be used to print 3D objects. They also support in printing them. The functional tool heads 304 can have multiple degrees of freedom, for example, 5, 6, or 6.
The extruding head may be fed with a material from which the 3D object can be built. An embodiment of the building material could be an amorphous, semi-crystalline, metallic, ceramic, carbon, or any other reinforced material.
“FIG. “FIG. FIG. FIG. 2 shows that, in addition to the extruding heads, other functional tool head can be used as corrective devices during the printing process. Corrective devices are the automatic working devices that assist in printing an object. They can correct defects in real-time. One or more defects can be created during the extruding process. One embodiment may have a variety of defects, including but not limited to: drooping/sagging; insufficient crystallinity; slow solidification; out of tolerance feature; excess polymer; delamination; overhangs; warping; adhesion between printed layers of an object. These can all lead to insufficient mechanical, chemical or thermal properties.
“In addition, the system 200 could include one or more monitoring devices such as quality-detecting devices 400. The 400-watt quality detecting device may monitor the printing process continuously and detect any defects that are forming in the object. The quality detecting device 400 may monitor the printing process in real-time. It can use x-rays, infrared or visual imaging to determine the dimensionality and contour of the object; or audio microphones to detect the dryness of the filament. Or defect sensing, which includes identification of the type and location of defects. Quality detecting devices 400 measure critical features of an object in order to verify that each feature falls within the acceptable tolerance set by the user.
“Quality detecting devices 400 can make use of detecting methods for monitoring the building process in real-time and identifying defects in the object. The detecting techniques include, but are not limited to, visual imaging, IR/thermal imagery, laser techniques and audio microphones to identify the characteristics of the defects, such as type, location, temperature, correction action and the like.
The quality detecting devices 400 keep an eye on the 3D object as it is being printed using the extruding heads. They also monitor the process in real-time and maintain a constant check on the printing process. The quality detecting devices 400 can detect defects in objects by using various techniques. The quality detecting devices 400 can then store the data captured in a data storage unit. This data stores the information that defines the defects such as their location, type, contour, dimensions, and critical features. The present invention allows for the recording and logging real-time events such as defects, corrections and the location of each defect within 3D space. It also records modifications to the object model or slicing parameters.
“The detected data can be transmitted to a controller such as a defect feedback control 402, which implements analyzing tools that predict correcting instructions 404. Correcting instructions describe the steps to be taken to correct defects and predict the object’s properties based on the type of defect detected by the quality detecting device 400. A defect feedback controller 402 could be an example of a correction module. It analyzes data collected from quality detecting devices 400 to generate feedback (including correcting instruction 404) depending on the characteristics of the defects. A slicing feedback control 408 analyzes the information about defects and build parameters to determine in-situ object geometry. mechanical, chemical, thermal, electrical, etc.). Based on the deficient data, the in-situ object properties and geometry are compared to the input object requirements. The appropriate slicing instruction 410 is generated for the slicing machine 300. To reduce future defects and meet object requirements, these slicing directions 410 modify the tool path instructions (206).
“In one embodiment, the system 200 to print a 3D object consists of a single controller that controls the extruding heads and corrective devices and generates the instructions.”
“The defect feedback control 402 can determine the properties of the object to be printed and the correcting instruction 404 based on the defects found and the object’s desired strength. The defect feedback controller 402 can also instruct corrective devices to perform the corresponding functions according to the correcting instructions. The controller 302 may receive the correcting instructions 404. This further controls the functional tools heads 304. The correcting instructions 404 are received by the functional tool heads. They instruct the tool head attachments (corrective devices 406) to be used. The corrective devices 406 then perform the functions required by the correcting instructions.
The corrective devices 406 may be attached to the functional tools 304 to perform a function to correct a corresponding defect. This function could include cooling, heating and milling the object, or deburring the object. The correction devices 406 can perform the function necessary to correct a specific defect.
For example, if quality detecting devices 400 detect that the printed layers are not adhering to each other and this results in an inaccurate geometry, reduced thermal conductivity, reduced mechanical strength, or similar, the defect feedback controller 402. determines that heating the deposited material is necessary for proper adhesion. The defect feedback controller 402 can determine whether there is heating. As the correcting instructions 404, the defect feedback controller 402 may determine?heating? and direct a corresponding corrective tool (406) to heat the deposited layers in order to ensure adhesion. The slicing feedback control 408 may alter the slicing directions 410 to address the identified defect. This will allow the tool path instructions (206) to be modified in order reduce the likelihood of future defects and meet object requirements. Modified slicing instructions could include decreasing the layer height, increasing material feed rate and/or increasing extrudate width.
The system 200 monitors the printing process in real-time and detects defects by using quality detecting devices 400. The controller 302 also provides an independent and automated control of corrective devices, based upon feedback analysis. This allows for the correction of defects in the object, and modification of appropriate tool path instructions (206), in real-time. This results in a 3D object that is free from defects.
“In one embodiment of the invention, the build apparatus may have a single functional head 304 with attachment points for attaching a plurality tools performing different functions.” The controller can send instructions to the functional tool head 304 to select the tool.
“Another embodiment of the invention allows the functional tool head to be attached to multiple tool attachments, where the controller controls the movement of each tool attachment. Each tool attachment contains an attachment point that provides an attachment means to the functional tool heads 304 for different functions in the 3D printing process. Each of the attachments, or arms, are the tools that make up the build apparatus. They are independent and can be driven automatically based on instructions from the controller 302 or the defect feedback controller 402.
The printing system can also provide a build report. A build report can be generated by the user device after the printing process is completed. A build engine on the device might generate a visual build report that displays each uncorrected and corrected defect in 3D space. This report will include information about the type of defect and its location within the object. An analyzing module on the device uses the information contained in the build report to determine the material properties of final objects based upon the type, number and location of uncorrected and corrected defects. An analyzing module can use finite element analysis or other techniques.
The build report compares the final object’s material properties to the user’s specifications. It also identifies any properties that are not in the specifications by using analyzing techniques. A user may use the information in the build reports to help decide whether to keep or throw away the final object. This is based on the properties of the final printed object as well as the details of the uncorrected and corrected defects. This is an important step in determining the value or suitability for the intended purpose of the final object.
Further, the build report can be used to resolve mechanical, thermal, and uncorrected defects in the built object. It may then be reprinted with the same building parameters and constraints. The build report can be used to optimize the tool path instructions206 for printing identical or similar objects. It also helps in determining the value of the final printed object. A finite element analysis may be used to determine the material properties of final objects and to decide whether or not to keep them.
“FIG. “FIG. Column 502 lists the possible defects that could occur during 3D printing. A defect could occur during printing, such as excess polymer being deposited by the first robot manipulator. Visual Imaging, Laser (504) may detect this type of defect. The defect feedback controller 402 will then determine the corrective actions (correcting instructions), which may include deburring or radiative heating (506). The appropriate functional tool heads 304 are then notified of the course of action. They can perform either deburring or radiative heating or tamping. The defect feedback controller 402. provides instructions to the appropriate functional tool heads 304. The functional tool heads 304 perform the function by moving in the x, y, and z axes. For correcting defects in 3D, the functional tool head 304 must be moved. The movement of functional toolhead 304 in an embodiment of the invention can be done in either a Cartesian mechanism, where the tool heads are moved in the X,Y, and Z directions, or through a non-cartesian method, where the functional tool heads can freely move in three-dimensional space.
“The slicing feedback control 408 can also generate slicing directions 410 to stop excess polymer being deposited in the subsequent layers. The slicing instructions could include increasing the layer height, decreasing material feed rate, or decreasing the extrudate thickness. This allows for a variety quality detecting techniques to detect defects during printing. The feedback controllers 402 or 408 may determine the correcting and slicing instruction 404.
“FIG. “FIG. 6” illustrates an example illustration in which functional tool heads 304 are attached at a variety of tool head attachments 604 that are used in additive manufacturing. FIG. FIG. 6 shows that each functional toolhead 304 may include a tool attachment point 602. A tool attaching point 602 can be used to attach a tool attachment 604 to a functional tool head 304. This may be used to fix a toolhead attachment 604 that is performing a particular function. Functional tool heads 304 allow the printing process to be performed in an automated manner. The functional tool heads 304 can be equipped with tool attachment 604 which performs a specific function. These attachments are attached to the tool attaching points 602 of functional tool head 304. The functional toolhead 304 might also pick up various fixtures. These fixtures are attached via the tool attaching points 602 to the functional head 304.
If a functional toolhead 304 is asked to cool, it may grab a fixture or attachment 604 and attach the specific tool attachment 604 via tool attaching point 602. If the functional toolhead 304 is asked to take a thermal image and it drops the cooling toolhead, it may pick up a fixture or attachment 604 and attach the specific tool attachment 604 via tool attaching point 602. The functionality of the functional toolhead 304 can be interchanged depending on the printing process.
“In another embodiment, functional tool heads 304 can perform dedicated functions such as heating, cooling, depositing build material and milling, deburring, laser heat, blowing or blowing air. Each functional tool head 304 is attached to the corresponding tool heads 604 via the tool attachment point 602.
“FIG. “FIG. 7” illustrates a flowchart that shows a method for additive manufacturing, which allows the printing of a 3D object. This process monitors the printing process and identifies and corrects any defects. A user can input a 3D file 202 via a device using step 702, where the 3D file defines the characteristics and dimensions of a 3D object. The embodiment of the invention may include a computer or other computing device. It may also include software for 3-D modeling, such as AutoCad, and similar programs. A third embodiment may contain a 3D data file that includes a CAD, STL, or COD file. Another embodiment may contain characteristics such as the object’s structural geometry, inherent material properties and mechanical, electrical, chemical and thermal properties. Another embodiment of additive manufacturing is extrusion-based printing or continuous fiber-based deposition processes. This includes fused deposition modeling, fused fil fabrication, and the like. Other methods include droplet-based jetting and the like.
“After receiving the 3D files 202, a first engine such as a slicer engine 300, separates the 3D files 202 into segments that run along arbitrary planes at step 704. The slicing engines 300 can also be used to separate the 3D file 202 into multiple slices along two-dimensional planes. After slicing the file 202 at step 706, a set 206 of tool path instructions is created using the slicing engines 300. These instructions are based on a set 204a and 204b of object property requirements and slicing parameters. To reduce future defects and meet object requirements, the tool path instructions 206 can also be adjusted in-situ using the slicing feedback control.
The build apparatus could include a number of functional tool heads, 304 and a variety of attachments that allow for multiple degrees of freedom of movement to print a 3D object. The functional tool heads 304 may have multiple attachments, such as 5, 6, or more degrees of freedom. Based on feedback analysis, the functional tool heads 304 work independently and simultaneously with each other. One or more attachments to the tool heads 304 may also be used as extruders, print heads, or deposition heads for depositing layers build material on the printer platform. Deposition head attachments may also be known as extruding heads 306 and can be controlled by a controller. For receiving tool path instructions, the controller 302 is still in communication with user device. At step 508, the controller might instruct the extruder head 306 to follow instructions 206 and deposit printable layers of a material to create the 3D object.
The controller 302 controls the movement of the functional head 304 in an embodiment. After receiving the tool path instruction (206) required to print the 3D objects, the controller 302 controls the movement and direction of the functional heads. Cartesian or non-Cartesian mechanisms can control the movement of the functional head 304. Cartesian movement allows the functional heads 304 to be moved along the X, Z, and Y-axes. Axial movement is not allowed. Non-Cartesian movement allows the functional heads 304 to freely move in any direction.
The extruding head 306 may be deposited layers of build material onto the printing platform. However, the object may have one or more defects that could further cause faults in geometry and inherent properties such as low mechanical strength. An embodiment may have drooping/sagging and insufficient crystallinity. Slow solidification, out-of-tolerance feature, air bubbles and excess polymer. Warping and adhesion can also occur between the printed layers.
The system includes one or more monitoring devices such as quality detecting device 400 to monitor the printing process continuously. Quality detecting devices 400 can use detecting techniques to detect defects in 3D objects being printed. These techniques can include visual imaging, IR/thermal, laser techniques, audio mics, and other techniques to detect the characteristics of defects, such as type, temperature, correction action, location, and so on. The quality detecting devices 400 can monitor the printing process continuously and detect defects that are forming in the object at step 710. Thermal sensors, cameras, lasers or any other image detection device, infrared devices to inspect the geometry of the object, microphones to record abnormal extrusion sounds to determine if the filament has dried properly, and similar devices are all part of the quality detecting devices 400.
“The present invention further provides a method for correcting defects in real-time while an object is being printed. One or more functional tool heads 304 can be used as corrective devices 406 to fix defects detected by quality detecting devices 400. One or more corrective device 406 is a tool head that performs one or more functions to correct one or several defects. The functions can include cooling, heating or milling the object, or deburring it.
“As soon the quality detecting device 400 detects defects and their features, such a location and type of defect location, they can store the defects data into a data storage module. The data defines the features such as location, type, contour, critical feature measurements, dimensions, and dimensionality of the built object. The present invention allows for the recording and logging real-time events such as corrections, defects, and location in 3D space.
“The data from the quality-detecting devices 400 can be fed to a controller such as a defect feedback control 402. The feedback controller 402 analyzes the data to generate correcting instructions 404. These instructions should be followed to fix the defects. An embodiment of this invention uses finite element analysis to predict the object’s properties based on the types of defects identified by quality detecting devices 400. The defect feedback controller 400 can be used to generate feedback (correcting instruction 404) depending on the characteristics of the defects.
After generating the correcting directions 404, the defect feedback control 400 may control corrective devices 406. It will instruct them to perform the corresponding functions based upon the feedback generated, including the correcting instruction 404. The corrective devices 406 are activated at 712 and can be used independently to correct the 3D objects’ defects during the printing process.
“At step 714, taking into account the defective data from the quality-detecting devices 400, controllers, such as a Slicing Feedback Controller 408, may modify the implemented cutting instructions 410 for slicing engines 300 to further separate the 3D data file. 202. To reduce future defects and to ensure that object requirements are met, the modified slicing directions 410 modify the tool path instruction 206.
After the printing and correcting processes are completed, the user device may generate a build report (step 716), which is based on the printing process and any corrections made. The feedback from the build volume may allow the user device to generate a visual build report that displays in 3D space all features and any uncorrected defects. An analyzing module on the device may use the information contained in the build report to determine the material properties of final objects based on type, location, and number of uncorrected defects. The report compares the final object’s actual material properties with the user’s specifications, and identifies any properties which are not in line with these specifications.
“In addition, the build report can help the user decide whether to keep or throw away the final object. It will include information about the expected inherent properties as well as the details of the uncorrected and corrected defects. This is an important step in determining the value of the final object. The build report can also be used to resolve mechanical, thermal, and uncorrected problems of the built object. It may then be reprinted with the same building parameters and constraints. The build report can be used to optimize the tool path instructions 206 for printing identical or similar objects. It also helps the user determine the value of the final printed object.
The present invention is a system and method for three-dimensional printing. It monitors the printing process in real time to identify any defects in the object. The present invention also allows for in-situ corrections of defects during printing by an automated and independent control of functional tool head based on feedback analysis.
“Following example may help you understand the invention clearly.”
“In one embodiment of the present invention, a 3D printer machine includes two independent controlled multi-axis functional tools heads. These functional tool heads could be robotic arms. Robotic arm X is composed of an extruder, while robotic arm Y acts as a real time correction device.
“Robotic arm X can be controlled by the toolpath instructions 206 generated in the CAD file.”
“Robotic arm Z can use a variety of interchangeable fixtures in order to correct part manufacturing defects. Considering, ?B? Consider?B?? A multi-axis system that includes D devices is used to detect defects in real time during production. D devices are quality-detecting devices. Image processing software determines the type, number, and location of defects. This information is passed to the robotic arm’s control software (feedback controller), which determines the correct course of action. Some defects cannot be corrected by robotic arm, but they are still stored in the data storage module. This information is used to create a final build report.
“Further Robotic arm Y picks the correct fixture with?A?” To correct the defect, functionality is provided. If the deposition site has not been affected, robotic arm X may continue extruding material. Otherwise, robotic arm X will wait until robotic arm Y has completed correcting the defect. This information is used to modify the printed object model and slicing parameter. The subsequent tool path instructions for robotic armX are then modified. Robotic armY performs the same operation to correct any defects during the entire build process.
The build report, which displays every defect and its location in the part, is generated after the build process has been completed. Based on the location, type, and number of uncorrected defects, this information can be used to predict the material properties for the final part.
“In an embodiment the functionality?A?” The functionality can include cooling, heating, or milling/deburring. The defect?B? in an embodiment is The defect?B? in an embodiment can include drooping/sagging or insufficient crystallinity, slow liquidification, out-of-tolerance feature, and other such things. The defect?C? Air bubbles, excess polymer or delamination, warping, adhesion among printed layers of an object, and the like.
“In an embodiment, a quality detecting device?D?” It can include visual imaging, IR/thermal and laser techniques.
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