Determine the optimal values ​​for additive manufacturing and / or 3D printing processes

Abstract

This disclosure relates to determining optimal values ​​for additive manufacturing and / or 3D printing processes. More specifically, it discloses machine logic (e.g., software) selecting from pre-existing manufacturing processes to produce physical parts of a new design, or parts reflecting a modified design relative to an earlier design. In some embodiments, the manufacturing process includes an additive manufacturing (AM) process. In some embodiments, the manufacturing process involves 3D printing.

Description

Technical Field

[0001] This invention relates generally to the field of additive manufacturing design, and more specifically to the application of such design in the market. Background Technology

[0002] The Wikipedia entry for "additive manufacturing" (June 21, 2021) states in part: "3D printing, or additive manufacturing, is the construction of three-dimensional objects from CAD or digital 3D models. The term '3D printing' can refer to the various processes in which materials are deposited, joined, or solidified under computer control to produce three-dimensional objects, where materials are typically added together layer by layer (such as plastics, liquids, or powder particles fused together). One of the key advantages of 3D printing is its ability to produce very complex shapes or geometries that would otherwise be impossible to construct by hand, including hollow parts or parts with internal truss structures to reduce weight." Additive manufacturing (AM) gained popularity in 2000, inspired by the theme of materials being added together (in any of a variety of ways). The term 3D printing still primarily refers to polymer technology, and AM is more likely to be used in the context of metalworking and end-use parts production than among polymer, inkjet, or stereolithography enthusiasts. Inkjet is the least familiar technology, even though it was invented in 1950 and is little known due to its complex nature. Until recently, the term "3D printing" was associated with low-cost or low-capacity machines. 3D printing and additive manufacturing reflect the theme of these technologies sharing material addition or inclusion throughout the 3D work envelope under automated control (footnote omitted).

[0003] According to the Additive Manufacturing Research Group at Loughborough University on July 12, 2021: "While the media likes to use the term '3D printing' as a synonym for all additive manufacturing processes, there are actually many separate processes that differ in their layer-making methods. Each process will vary depending on the materials and machine technology used."

[0004] Currently, at least seven existing types of additive manufacturing (AM) have been identified as follows: photopolymerization, material jetting, binder jetting, material extrusion, powder bed fusion, sheet lamination, and directional energy deposition. It should be noted that "additive manufacturing," as used herein, can refer to combinations of these types, combinations of AM with conventional manufacturing techniques, and / or other types of AM not explicitly mentioned herein. Summary of the Invention

[0005] According to an aspect of the invention, a method, computer program product, and / or system are provided to perform the following operations (not necessarily in the following order): (i) receiving a product specification dataset including information indicating the design of a physical product; (ii) receiving a plurality of manufacturing process datasets, each of the plurality of manufacturing process datasets including information indicating a manufacturing process that can be used to manufacture the physical product, such that the plurality of manufacturing process datasets correspond to a plurality of manufacturing processes; and (iii) selecting an optimal manufacturing process from the plurality of manufacturing processes by machine logic.

[0006] According to an aspect of the invention, a method, computer program product, and / or system are provided to perform the following operations (not necessarily in the following order): (i) receiving a product specification dataset including information indicating the design of a physical product; (ii) receiving a plurality of manufacturing process datasets, each of the plurality of manufacturing process datasets including information indicating a manufacturing process that can be used to manufacture the physical product, such that the plurality of manufacturing process datasets correspond to a plurality of manufacturing processes; and (iii) selecting an optimal manufacturing process from the plurality of manufacturing processes by machine logic; wherein the optimal manufacturing process includes at least one additive manufacturing (AM) operation.

[0007] According to an aspect of the invention, a method, computer program product, and / or system are provided to perform the following operations (not necessarily in the following order): (i) receiving a product specification dataset including information indicating the design of a physical product; (ii) receiving a plurality of manufacturing process datasets, each of the plurality of manufacturing process datasets including information indicating a manufacturing process that can be used to manufacture the physical product, such that the plurality of manufacturing process datasets correspond to a plurality of manufacturing processes; and (iii) selecting an optimal manufacturing process from the plurality of manufacturing processes by machine logic; wherein the optimal manufacturing process includes at least one three-dimensional (3D) printing operation. Attached Figure Description

[0008] Figure 1 This is a block diagram of a first embodiment of the system according to the present invention;

[0009] Figure 2 This is a flowchart illustrating a method of the first embodiment, which is at least partially performed by the system of the first embodiment;

[0010] Figure 3 This is a block diagram illustrating the machine logic (e.g., software) portion of the system of the first embodiment;

[0011] Figure 4 The screenshot view generated by the system in the first embodiment; and

[0012] Figure 5 This is a flowchart illustrating a method according to a second embodiment of the present invention. Detailed Implementation

[0013] This detailed description is divided into the following sections: (i) hardware and software environment; (ii) example embodiments; (iii) further comments and / or embodiments; and (iv) definitions.

[0014] i. Hardware and software environment

[0015] This invention can be a system, method, and / or computer program product with any possible level of technical detail integration. The computer program product may include a computer-readable storage medium (or media) having computer-readable program instructions thereon for causing a processor to execute aspects of the invention.

[0016] A computer-readable storage medium can be a tangible means for retaining and storing instructions for use by an instruction execution device. A computer-readable storage medium can be, for example, but not limited to, electronic storage devices, magnetic storage devices, optical storage devices, electromagnetic storage devices, semiconductor storage devices, or any suitable combination of the foregoing. A non-exhaustive list of more specific examples of computer-readable storage media includes: portable computer disks, hard disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), static random access memory (SRAM), portable compact disk read-only memory (CD-ROM), digital universal disk (DVD), memory sticks, floppy disks, mechanical encoding devices such as punch cards or protrusions in slots having instructions recorded thereon, and any suitable combination of the foregoing. As used herein, a computer-readable storage medium should not be construed as a transient signal itself, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through waveguides or other transmission media (e.g., light pulses through fiber optic cables), or electrical signals transmitted through wires.

[0017] Therefore, a "storage device" is defined as anything made or adapted to store computer code in a manner that allows a computer processor to access the computer code. Storage devices typically include storage media, which are materials on which or on which the computer code is stored. A single "storage device" may have: (i) multiple discrete portions spaced or distributed (e.g., a group of six solid-state storage devices, each located in one of six laptop computers that collectively store a single computer program); and / or (ii) may use multiple storage media (e.g., a set of computer code stored partly as a magnetic field in the computer's non-volatile memory and partly in a set of semiconductor switches in the computer's volatile memory). The term "storage media" should be interpreted to encompass situations where multiple different types of storage media are used.

[0018] The computer-readable program instructions described herein can be downloaded from a computer-readable storage medium to a suitable computing / processing device via a network (e.g., the Internet, a local area network, a wide area network, and / or a wireless network), or to an external computer or external storage device. The network may include copper cables, optical fibers, wireless transmissions, routers, firewalls, switches, gateway computers, and / or edge servers. A network adapter card or network interface in each computing / processing device receives the computer-readable program instructions from the network and forwards them to a computer-readable storage medium within the suitable computing / processing device.

[0019] Computer-readable program instructions used to perform the operations of this invention may be assembly instructions, instruction set architecture (ISA) instructions, machine instructions, machine-dependent instructions, microcode, firmware instructions, state setting data, or source code or object code written in any combination of one or more programming languages, including object-oriented programming languages ​​(such as Smalltalk, C++, etc.) and conventional procedural programming languages ​​(such as the "C" programming language or similar programming languages). The computer-readable program instructions may be executed entirely on a user's computer, partially on a user's computer, as a standalone software package, partially on a user's computer and partially on a remote computer, or entirely on a remote computer or server. In the latter case, the remote computer may be connected to the user's computer via any type of network (including a local area network (LAN) or a wide area network (WAN)) or may be connected to an external computer (e.g., via the Internet using an Internet service provider). In some embodiments, electronic circuitry including, for example, programmable logic circuitry, field-programmable gate arrays (FPGAs), or programmable logic arrays (PLAs) may be personalized to execute computer-readable program instructions by utilizing state information from the computer-readable program instructions in order to perform aspects of this invention.

[0020] The present invention will now be described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It should be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer-readable program instructions.

[0021] These computer-readable program instructions may be provided to a processor of a general-purpose computer, a special-purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions / actions specified in one or more blocks of a flowchart and / or block diagram. These computer-readable program instructions may also be stored in a computer-readable storage medium that causes a computer, programmable data processing apparatus, and / or other device to operate in a particular manner, such that the computer-readable storage medium storing the instructions includes an article of manufacture containing instructions that implement aspects of the functions / actions specified in one or more blocks of a flowchart and / or block diagram.

[0022] Computer-readable program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus, or other device to produce computer-implemented processing, such that the instructions executed on the computer, other programmable apparatus, or other device perform the functions / actions specified in one or more boxes of a flowchart and / or block diagram.

[0023] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present invention. Each block in a flowchart or block diagram may represent a module, segment, or portion of instructions, including one or more executable instructions for implementing a specified logical function. In some alternative implementations, the functions marked in the blocks may occur in a different order than indicated in the figures. For example, depending on the functions involved, two consecutively shown blocks may actually be executed substantially simultaneously, or these blocks may sometimes be executed in reverse order. It should also be noted that each block in the block diagrams and / or flowcharts, and combinations of blocks in the block diagrams and / or flowcharts, can be implemented using a dedicated hardware-based system that performs the specified function or action or executes a combination of dedicated hardware and computer instructions.

[0024] like Figure 1As shown, the networked computer system 100 is an embodiment of the hardware and software environment used in various embodiments of the present invention. The networked computer system 100 includes: a server subsystem 102 (sometimes more simply referred to herein as subsystem 102); a model and execution engine repository 104; an AM (additive manufacturing) subsystem 106; a 3D (three-dimensional) printer subsystem 108; and a communication network 114. The server subsystem 102 includes: a server computer 200; a communication unit 202; a processor group 204; an input / output (I / O) interface group 206; a memory 208; permanent memory 210; a display 212; external devices 214; random access memory (RAM) 230; a cache 232; and a program 300.

[0025] Subsystem 102 may be a laptop computer, tablet computer, netbook computer, personal computer (PC), desktop computer, personal digital assistant (PDA), smartphone, or any other type of computer (see the definition of "computer" in the Definitions section below). Program 300 is a collection of machine-readable instructions and / or data for creating, managing, and controlling certain software functions, which will be described in detail below in the Example Embodiments section of the Detailed Implementation section.

[0026] Subsystem 102 is capable of communicating with other computer subsystems via communication network 114. Network 114 may be, for example, a local area network (LAN), a wide area network (WAN) such as the Internet, or a combination of both, and may include wired, wireless, or fiber optic connections. Generally, network 114 may be any combination of connections and protocols that support communication between server and client subsystems.

[0027] Subsystem 102 is shown as a block diagram with numerous double arrows. These double arrows (without individual reference numerals) represent a communication structure that provides communication between the various components of subsystem 102. This communication structure can be implemented using any architecture designed to transfer data and / or control information between processors (such as microprocessors, communication and network processors, etc.), system memory, peripheral devices, and any other hardware components within the computer system. For example, the communication structure can be implemented at least partially using one or more buses.

[0028] Memory 208 and persistent memory 210 are computer-readable storage media. Typically, memory 208 may include any suitable volatile or non-volatile computer-readable storage medium. It should be further noted that now and / or in the near future: (i) external device 214 may be able to provide some or all of the memory for subsystem 102; and / or (ii) devices external to subsystem 102 may be able to provide memory for subsystem 102. Memory 208 and persistent memory 210: (i) store data in a transient manner smaller than a signal in transit; and (ii) store data on a tangible medium (such as a magnetic or optical domain). In this embodiment, memory 208 is volatile storage, while persistent memory 210 provides non-volatile storage. The medium used for persistent memory 210 may also be removable. For example, a removable hard disk drive may be used for persistent memory 210. Other examples include optical discs and disks, thumb drives, and smart cards, which are inserted into drives for transfer to another computer-readable storage medium that is also part of persistent memory 210.

[0029] Communication unit 202 provides communication with other data processing systems or devices outside subsystem 102. In these examples, communication unit 202 includes one or more network interface cards. Communication unit 202 can provide communication using either or both physical and wireless communication links. Any software modules discussed herein can be downloaded to a persistent storage device (such as persistent memory 210) via a communication unit (such as communication unit 202).

[0030] I / O interface group 206 allows data input and output to other devices that can be locally connected to server computer 200 in data communication. For example, I / O interface group 206 provides connectivity to external device group 214. External device group 214 typically includes devices such as keyboards, keypads, touchscreens, and / or other suitable input devices. External device group 214 may also include portable computer-readable storage media, such as thumb drives, portable optical discs or disks, and memory cards. Software and data (e.g., program 300) used to implement embodiments of the invention can be stored on such portable computer-readable storage media. I / O interface group 206 is also communicatively connected to display 212. Display 212 is a display device that provides a mechanism for displaying data to a user and can be, for example, a computer monitor or a smartphone display screen.

[0031] In this embodiment, program 300 is stored in persistent memory 210 for access and / or execution by one or more computer processors of processor group 204 (typically via one or more memories of memory 208). Those skilled in the art will understand that program 300 may be stored in a more distributed manner during its runtime and / or when it is not running. Program 300 may include machine-readable and executable instructions and / or substantial data (i.e., the type of data stored in a database). In this particular embodiment, persistent memory 210 includes a magnetic hard disk drive. For the sake of naming some possible variations, persistent memory 210 may include a solid-state hard disk drive, a semiconductor storage device, a read-only memory (ROM), an erasable programmable read-only memory (EPROM), flash memory, or any other computer-readable storage medium capable of storing program instructions or digital information.

[0032] The procedures described herein are identified based on their implementation in specific embodiments of the invention. However, it should be understood that any particular procedural terminology used herein is for convenience only, and therefore the invention should not be limited to use only in any particular application identified and / or implied by such terminology.

[0033] Various embodiments of the invention have been described for illustrative purposes, but are not intended to be exhaustive or limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein has been chosen to best explain the principles of the embodiments, their practical application, or technical improvements to technologies found in the market, or to enable those skilled in the art to understand the embodiments disclosed herein.

[0034] ii. Exemplary embodiments

[0035] like Figure 1 As shown, the networked computer system 100 is an environment in which the example methods according to the present invention can be executed. Figure 2 As shown, flowchart 250 illustrates an example method according to the present invention. Figure 3 As shown, program 300 executes or controls the execution of at least some of the method operations in flowchart 250. The following paragraphs will now be extensively referenced in relation to the process. Figure 1 , 2 The following section, box 3, will be used to discuss this approach and the associated software.

[0036] Processing begins in operation S255, where input module (“mod”) 302 receives a dataset indicating the design of physical components (e.g., gears or forklifts).

[0037] The process proceeds to operation S260, where input module 302 receives three “models” (hereinafter referred to as the first model, the second model, and the third model) from the model and execution storage 104. Each model represents a different additive manufacturing process that can be used to manufacture the physical part specified by the data received in operation S255.

[0038] The process proceeds to operation S265, in which the processing module 304 compares and evaluates the manufacturing time required for each model.

[0039] The process proceeds to operation S270, in which module 304 compares and evaluates the manufacturing costs required for each model.

[0040] The process proceeds to operation S275, in which module 304 compares and evaluates the opportunity cost of each model.

[0041] The process proceeds to operation S277, in which module 304 compares and evaluates the availability of materials required for each model (e.g., raw materials for physical components, materials consumed by the manufacturing process itself).

[0042] The process proceeds to operation S279, in which module 304 compares and evaluates the quality / reliability of the physical component instantiation to be performed during the manufacturing process of each given model.

[0043] The process proceeds to operation S281, in which module 304 selects the optimal manufacturing process (and associated model and / or execution engine) for the instantiation of the physical part. In this instance, the manufacturing process corresponding to the third model has been selected.

[0044] Processing continues to operation S290, where: (i) the third model 116 is sent to the additive manufacturing subsystem 106 (see...) Figure 4 (ii) the physical part is instantiated using the selected optimal additive manufacturing process. This is in Figure 4 As shown, the additive manufacturing controller 115 controls the additive manufacturing hardware 112 to manufacture a new product 110 using an output module 306, which is a physical instantiation of the product design received at operation S255.

[0045] iii. Further comments and / or implementation methods

[0046] Some embodiments of the present invention recognize the following facts, potential problems, and / or potential areas of improvement relative to the prior art: (i) in the additive manufacturing space, there are multiple factors that can affect the results and their quality; (ii) inconsistency in the quality of manufactured parts is a major obstacle to large-scale adoption; and / or (iii) factors that may affect the additive manufacturing process include CAD (computer-aided design) design and the geometry, topology, operating conditions (e.g., spatiotemporal temperature distribution), and the source and type of raw materials (e.g., powder composition or powder size distribution).

[0047] Some embodiments of the present invention recognize the following facts, potential problems, and / or potential areas of improvement relative to the prior art: (i) in the manufacturing field, several common sub-components can produce different end products (e.g., bearings can be used in a large number of different end products); (ii) manufacturers (marketers) may have perfected methods for manufacturing sub-components using AM after several trials and errors (e.g., predictive and simulation models that can estimate results before printing parts); (iii) the knowledge and insights that manufacturers have gained in using AM to build sub-components may be of great value to other interested manufacturers; (iv) publishing AM designs and processes is also a way for manufacturers to monetize their created additive manufacturing processes; and / or (v) if manufacturers (publishers) are seeking to publish their unique AM processes in the market, there is a need for a way to determine the value of the process and to recommend / rating it to other interested manufacturers to aid their decision-making.

[0048] Some embodiments of the present invention recognize the following facts, potential problems, and / or potential areas of improvement relative to the prior art: (i) additionally, if another manufacturer (buyer) is seeking to utilize an additional printing process for a commonly used sub-component, that person can obtain recommendations regarding the AM design that will best suit his input and operating conditions; and / or (ii) for example, if a manufacturer (buyer) wants to use AM to print bearings of a specific specification, he can utilize a certified AM process from another manufacturer (publisher) to make his AM steps easier. The following paragraphs (with two (2) use case examples) describe potential problems associated with current AM.

[0049] There are several applications of additive manufacturing, in which several suppliers have specific processes for achieving certain goals through component reinforcement, surface treatment, and component re-profile in multiple scenarios. These scenarios can be: repurposing existing parts into new spare parts in a short period of time, rather than building new parts; combining multiple material properties to achieve specific goals of a part profile, which can be achieved by a specialized manufacturer with unique processes that provide the required part properties; adding specific thickness and profile in a single manufacturing step; enhancing existing parts by resurfacing the outer surface for different physical properties; and so on. Two specific use cases (2) are mentioned below:

[0050] Use Case 1 - Manufacturing Spare Parts from Existing Spare / Replacement Parts: Sometimes in industry, it may be easier to utilize existing parts, apply additive manufacturing (AM) on top of them, and produce the desired spare part instead of manufacturing it from scratch. For some parts, a re-engineered part design may be necessary: ​​(i) increased performance issues (increased power throughput over a short period); and (ii) increased strength or other material properties – a new layer can be added on top of an existing part / replacement to enhance its strength, for example, drill bits and mining tools. There are several instances in component design and use where variations of the component design are needed as replacements with minimal design adjustments. This is common in industry for problem-solving and can be beneficial when spare parts are not readily available or obtaining spare parts is neither time-efficient nor cost-effective. In such cases, it is necessary to build by adapting existing spare sectors / components using AM.

[0051] Use Case 2 - New Part Variants: This is another application of AM where variations of parts not manufactured in conventional ways are required. This can be accomplished to perform very specific tasks (such as a forklift attempting to lift a load with obstacles) or to overcome specific problems, like with drilling / mining machines. Suppose you encounter a material like rock rather than soil; this material has different strength characteristics than the machine or drill head is designed for. In such cases, it may be necessary to increase the transmitted force (which may require changing the gear ratio).

[0052] Furthermore, for example, a component in a machine may age due to multiple out-of-profile events, resulting in greater wear on the component profile. Consequently, the component's power transmission / strength characteristics may have changed from the specifications given in the example below.

[0053] As an example, suppose a forklift has a design capacity of 1 ton, but needs to be lifted to, say, 1.1 tons. While the additional 10% load may already be met by safety features built into the forklift, suppose that strength characteristics have decreased with age because the forklift must navigate small obstacles in the lift at the edge and there are several knocking events that provide resistance to the load gear teeth. In such a case: (i) a new forklift can be ordered and waited for, which could cause significant delays; or (ii) the reference gear ratio of the power lift is changed (implying that, in addition to material characteristics, the forklift is capable of delivering torque for an additional load). Therefore, suppose that 4 teeth need to be added to the existing gears to accommodate the additional load. In this scenario, suppose there are 100 teeth on the gears with similar / slightly different radii. This requires reassembling into 104 gears using some AM processes.

[0054] In both scenarios, for example, some other manufacturer (Manufacturer A) has AM processes and software that can modify gears, and additional materials can be obtained from different sources. Manufacturer A has a process / simulation model that it may not want to share, but can share as an execution engine. Therefore, it will be necessary to integrate the method with the model from Manufacturer A, combining AM method steps, while also considering the different materials to be used and out-of-profile operating parameters (operating quality and constraints) that can be accommodated.

[0055] Some embodiments of the present invention may include one or more of the following operations, features, characteristics, and / or advantages with reference to the situations described in the preceding paragraphs: (i) employing a Manufacturer A model that conforms to in-profile requirements (the model may have secure packaging to protect its trade secrets). In-profile requirements are generally variations that need to be superimposed on the component to produce changes; and / or (ii) applying different implementation points: (a) required parameters (e.g., AM material type) and out-of-profile parameters (e.g., the forklift needs to overcome obstacles that apply thrust in addition to lifting the load, thus requiring additional force) requirements; (b) performing multiple simulations to derive AM calculations that satisfy both in-profile and out-of-profile parameters for the current requirements; and (c) catering to other in-profile (normal operation) and out-of-profile events seen by Manufacturer A, which are captured as out-of-profile operational instances and may be a library of dozens / hundreds of events captured over several instances and time periods. For example, impacting obstacles during movement, hitting harder surfaces or blocks during drilling / surfacing, and / or (d) the computing engine in a home organization may have models of the devices used to simulate them, but new material properties from manufacturer A in their security model must be invoked billions of times, and therefore, instead of service calls in pure SaaS (Software as a Service), the security-wrapped model is shared with limited time and functionality, and local embedding will be computationally more efficient. The model is capable of integrating and recalculating different combinations of original components, different AM processes from different specialized manufacturers, and physical properties and operations that change in both in-profile and out-of-profile events, to determine which manufacturer from a set of manufacturers and which component from a set of potentially valuable components meets the requirements for recommendation driven by time, cost, and opportunity cost for selection.

[0056] The following two (2) paragraphs describe the current technology in relation to the differences from 3D printing.

[0057] 3D printing creates parts or objects by jetting composite materials layer by layer into a mold, with or without a reinforcing frame. These jets can have varying thicknesses. The overall structural strength can be measured when the structure or part is fully printed. Because the jetted layers are covered, the underlying material bonding structure is unique, exhibiting strong adhesion on flat surfaces and weaker adhesion on extruded or covered surfaces. This may not be suitable for parts subjected to shear forces that require a volume of material for a specific 3D space to be held together in all three dimensions. Therefore, 3D printing is not suitable for manufacturing all types of parts.

[0058] Additive manufacturing primarily involves enhancing the surface of existing parts by covering multiple layers with materials used for adhesive layers. These materials possess properties that produce higher strength in extrusion or overlay processes of some material types. However, based on the environment of pouring additive mixtures to fill in 3D space, different manufacturers may have created unique processes to create multiple profiles on top of base parts with similar or dissimilar profiles. They will also have models of their processes and subsequent material strength assessments, which can be made available in protected models for others to incorporate into their models for calculating usage patterns.

[0059] Some embodiments of the present invention may include one or more of the following operations, features, characteristics, and / or advantages: (i) enabling efficiency in additive manufacturing processes, both rating and qualifying published AM processes, and supporting interested buyers in selecting methods / processes to address their specific needs; (ii) recommendations for rating published process models, said recommendations being based on: (a) a knowledge base of similar AM processes, (b) usage history and results, (c) differences of the proposed AM design relative to other designs, (d) comparison with conventional manufacturing processes, (e) published quality results utilizing the proposed AM design, such as structural stability and fit to the design, and (f) repeatability of the proposed AM design. (g) The ability to use knowledge graphs to interpret recommendations, and / or (h) The ability to combine feedback and performance proofs under new conditions based on market usage in the model; and / or (iii) The ability to recommend designs / processes to interested manufacturers / buyers based on: (a) the output conditions of interested buyers (such as part type, design specifications of production parts), (b) the operating conditions of interested buyers (such as planned AM processes), (c) the input parameters of the process (such as planned RM sources, powder type), (d) the history of similar requirements and knowledge stores available for AM designs, (e) AM relative to traditional decision points, and / or (f) The ability to capture performance evidence under different conditions as feedback to the model.

[0060] Some embodiments of the present invention may include one or more of the following operations, features, characteristics, and / or advantages: (i) the ability to integrate protected process steps / information into deep simulation engineering models for calculating components modified by AM, so as to enable the use of digital dual models or pure simulation (high frequency 10 Hz) for calculation. 12(i) Using a planned operation mode with small steps; (ii) Reusing components with different compositions not used in inventory, which can be used as the basis for AM and assessing suitability; (iii) Running multiple simulations across suppliers (multiple manufacturers can provide their processes and models to create components) to evaluate the best available options for creating new components using AM, which will reduce the time to create replacements / spare parts; (iv) Profile-exclusive events can drive the suitability of one manufacturing process for other manufacturing processes; (v) Existing profile surfaces are prepared for laying additional material to enhance required strength, such as in each tooth of a gear; (vi) Creating conduits for the flow of the new material while establishing the bond strength and simulating the establishment using the supplier's safety model; and / or (vii) Checking the strength while simulating possible profile events.

[0061] like Figure 5 As shown, flowchart 500 includes: capturing the initial state of raw materials S502; actions of the first procedure S504; actions of the second procedure S516; and actions of the third procedure S524. Actions of the first procedure S504 include: performing a raw material quality assessment (box S506); obtaining internal operating conditions (box S508); obtaining AM equipment type (box S510); obtaining historically used key AM processes (box S512); and obtaining recommended AM internal steps (box S514). Actions of the second procedure S516 include: searching external AM models to find the target (box S518); calling an external AM model service with relevant parameters (box S520); and obtaining recommended AM steps from the external AM service to achieve the target (box S522). Actions of the third procedure S524 include: comparing and ending the decision (box S526); and recommending the best AM steps (box S528).

[0062] Some embodiments of the present invention may include one or more of the following operations, features, characteristics, and / or advantages: (i) a platform comprising various AM processes from different entities, applicable to build a desired product by ranking different available AM ​​processes based on possible parameters of an achievable product, given intermediate available components; (ii) using a knowledge graph to utilize differences in product parameters from different AM processes; (iii) the ability to incorporate performance feedback to update different AM processes by finding differences between simulated and actual performance; (iv) no product redesign required to match the process; (v) each entity allows the requester's AM-based product modeler to connect to the AM process modeler of the manufacturing entity; (vi) a secure method for determining the construction of the final product / profile using the AM process modeler; (vii) determining whether the required physical parameters—profile, strength, shear force, surface hardness, and others—will be met; and / or (viii) determining the performance of the final product with nonlinear effects using weather conditions during the simulated process.

[0063] Some embodiments of the present invention may include one or more of the following operations, features, characteristics, and / or advantages: (i) rating a set of published processes and methods by different AM manufacturers, which can be used to create a final product using a given available intermediate product and applicable AM ​​processes from a database; (ii) comparing the process impact of AM processes on the final product or the parameters that the final product will exhibit; (iii) including methods for interpreting how the final product will have specified performance parameters that can be constructed from AM process characterization; (iv) combining feedback, performance verification of models under different conditions, and design repeatability; and / or (v) including methods for meshing or linking product and process simulators together, which will generate product characteristics or display the performance of products developed by AM.

[0064] Some embodiments of the present invention may include one or more of the following operations, features, characteristics and / or advantages: (i) determining which buyer conditions profiles must be used for products developed from intermediate AM components and whether they will be implemented and affect process model selection or comparison with conventional methods; (ii) describing the capture of performance evidence as feedback to the model under different conditions; and / or (iii) considering the operating conditions that the final product design must meet and how the AM 3D printing process contributes to the final physical performance parameters of the product.

[0065] Some embodiments of the present invention may include one or more of the following operations, features, characteristics, and / or advantages: (i) a viewing platform in which different AM processes are compared based on products that can be built from intermediate components, and a knowledge graph is used to verify the combined simulation of the product and AM process model if the physical characteristics of the resulting product meet the specifications required for operations outside the profile, wherein the process model is provided in a secure manner to protect any confidentiality of the additive manufacturing process(s) involved while meeting the high-frequency requirement of combined simulations that can be performed in a containerized secure environment; (ii) recommendations: (a) recommended ratings of products built using different process models based on the different conditions explained above, and / or (b) recommended models for customers to use based on specific customer requirements, operating conditions, and raw materials; (iii) enabling the sharing of process models with multiple subscribers (customers) to apply process simulations by feeding in operational (in-profile) and out-of-profile parameters; (iv) including a system that can accept recommended models and use them as executable programs for process simulations; and / or (v) the ability to determine the feasibility or match of manufactured products with customer requirements using simulation models of the product and the process links (from intermediate products to build products).

[0066] Some embodiments of the present invention may include one or more of the following operations, features, characteristics and / or advantages: (i) comparing AM with conventional methods to determine what is appropriate in a given situation; (ii) determining what is outside the operational conditions of buyer profiles when selecting models or comparing with conventional methods; and / or (iii) describing evidence of capturing performance under different conditions as feedback to the model.

[0067] Some embodiments of the present invention may include one or more of the following operations, features, characteristics, and / or advantages: (i) describing a method for identifying and recommending process models across customers, users, manufacturers, or markets to apply AM process simulation by feeding operational (in-profile) and out-of-profile parameters, basic raw materials, or products to be transformed into desired outputs via AM; (ii) including simulation factors in model rating, performance verification, repeatability, etc.; (iii) using knowledge graphs to explain the performance of selected models and the factors leading to their selection; (iv) the system can accept these client models and use them as executables to perform extensive process simulations to obtain alternatives for process selection, interpret the process using knowledge graphs, and ensure compliance with operational and out-of-profile conditions; (v) providing a rating mechanism for model selection; (vi) focusing on selecting processes for transforming raw materials or other semi-finished / finished products into new and modified products, respectively; and / or (vii) describing a method for constructing a history that incorporates buyer output conditions, similar requirements enhanced in the AM process assessment both in the profile and outside the profile parameters.

[0068] iv. Definition

[0069] The term "invention" should not be regarded as an absolute indication that the subject matter described by the term "invention" is covered by the filed claims or by the claims finally published after a patent lawsuit; although the term "invention" is used to help the reader get a general sense, the disclosure of such senses is considered potentially new, and such understanding as indicated by the use of the term "invention" is provisional and temporary, and will be changed during the patent defense process as relevant information is developed and as the claims are potentially amended.

[0070] Example: See the definition of "invention" above - similar considerations apply to the term "example".

[0071] And / or: includes or; for example, A, B, "and / or" C means that at least one of A, B, or C is true and applicable.

[0072] Includes / includes / includes: unless otherwise expressly stated, it means "including but not limited to".

[0073] Module / Submodule: Any group of hardware, firmware, and / or software that is operable to perform a certain function, without regard to whether the module is: (i) in a single local vicinity; (ii) distributed over a wide area; (iii) located in a single adjacent region within a larger software code segment; (iv) located within a single software code segment; (v) located in a single storage device, memory, or medium; (vi) mechanically connected; (vii) electrically connected; and / or (viii) a data communication connection.

[0074] Computer: Any device with significant data processing and / or machine-readable instruction reading capabilities, including but not limited to: desktop computers, mainframe computers, laptop computers, field-programmable gate array (FPGA) based devices, smartphones, personal digital assistants (PDAs), wearable or plug-in computers, embedded device type computers, and application-specific integrated circuit (ASIC) based devices.

Claims

1. A method for re-manufacturing a gear component of a machine, the gear component defining a gear ratio characteristic of the machine, the method comprising: receiving a product specification data set comprising information indicative of a first gear design, the first gear design defining a first gear ratio for use in the machine; receiving a manufacturing process data set, the manufacturing process data set comprising information indicative of an additive manufacturing process that can be used to transform a first gear made according to the first gear design into a second gear made according to a second gear design by adding at least one tooth to the first gear, the second gear design defining a second gear ratio for use in the machine; using the manufacturing process data set to transform a physically present first gear made according to the first gear design into a physically present second gear made according to the second gear design; and physically installing the second gear in the machine to operate the machine according to the second gear ratio to re-purpose the first gear.

2. The method of claim 1, wherein the machine is a drilling machine for drilling into the ground, the gear being used in a power system of the drilling machine.

3. The method of claim 1, wherein, the machine is a forklift truck for lifting and transporting a load, the gear being used in a power lift assembly of the forklift truck.

4. The method of claim 1, wherein, the first gear design has a different gear radius than the second gear design.

5. A computer system comprising: a computer readable memory unit, and a computer processor coupled to the computer readable memory unit, the memory unit comprising program instructions that, when executed by the computer processor, implement the method of any of claims 1-4.

6. A computer program product comprising program instructions executable by a processor to implement the method of any of claims 1 to 4.

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