Method for creating manufacturing plan for additive manufacturing of object by means of 3D printing

Abstract

The invention relates to a method (100) for creating a manufacturing plan (50) for additive manufacturing of an object (20) by means of 3D printing by means of at least one print head (40) of a 3D printer (30), comprising at least the following steps: providing (110) a three-dimensional model (21) of the object (20) to be manufactured; and-optimizing (120) the manufacturing plan (50) such that a filling process (130) of the printhead (40) is arranged into the manufacturing plan (50) according to the three-dimensional model (21) of the object (20).

Description

Technical Field

[0001] This invention relates to a method for additively manufacturing objects from any initial material (e.g., plastic or metal) using 3D printing. Background Technology

[0002] When using 3D printing to additively manufacture objects, a so-called slicer is typically used to convert the object's three-dimensional model into a specific manufacturing plan for that object. This manufacturing plan is directly understood and executed by the 3D printer. Numerous parameters can be set in the slicer. For example, one can choose which initial material to use, at what infill level to fill the cavities inside the object, to what temperature to heat the initial material, or at what speed to move the print head that adds material to the object.

[0003] DE 10 2020 208 175 A1 discloses a method for creating a manufacturing plan for an additive manufacturing object using 3D printing, wherein a three-dimensional model of the object to be manufactured is provided.

[0004] Furthermore, a printhead for a 3D printer is known from DE 10 2021 202 649 A1, which is adapted to implement a method for providing a printable melt to operate the printhead for the 3D printer, wherein the process of filling the printhead is repeated during print preparation and arbitrarily repeated during the printing of the part.

[0005] As is well known, depending on the printhead, the filling or filling process is always performed when the printhead has reached a predefined piston stroke, but at the latest when the printhead volume is empty. This operation is repeated throughout the duration of the entire printing process. Summary of the Invention

[0006] The objective of this invention is to provide a method for creating a manufacturing plan for an additive manufacturing object using at least one print head of a 3D printer via 3D printing, wherein the method optimizes the manufacturing plan and improves the part quality of the printed object.

[0007] Within the framework of this invention, a method has been developed for creating a manufacturing plan for an additive manufacturing object using at least one printhead of a 3D printer via 3D printing.

[0008] The method according to the invention for creating a manufacturing plan for an additively manufactured object using at least one printhead of a 3D printer via 3D printing includes at least the following steps: providing a three-dimensional model of the object to be manufactured; and optimizing the manufacturing plan such that the infilling process of the printhead is arranged into the manufacturing plan according to the three-dimensional model of the object. This achieves the modification of process parameters such that they are executed depending on the object or part, and advantageously improves the manufacturing plan.

[0009] The manufacturing plan is optimized so that the printhead filling process is arranged into the manufacturing plan according to the object's 3D model. This ensures that the filling process is shifted in the manufacturing plan in a way that optimizes the part, thereby enabling the print layer to be applied to the part-optimized position.

[0010] The method according to the invention advantageously avoids visible differences in the printed layers that could result from interruptions in the printing process during the filling process.

[0011] This allows for the optimization of component characteristics, as well as the improvement of the component's appearance and layer adhesion.

[0012] The filling process is performed, in particular, during a filling pause, and the printing process or printing program begins, in particular, with the start of printing. The filling process may also be referred to as refilling.

[0013] Typically, software, known as slicer software, serves as the intermediary between the 3D model and the 3D printer. This software prepares the 3D model for the printing process, where various parameters (e.g., extrusion speed, printhead speed, temperature, wall thickness, infill parameters, etc.) can be set. The method according to the invention extends these settings regarding the infill process, allowing these infill processes to be advantageously arranged according to the part.

[0014] The changes to the manufacturing plan are additionally aimed at optimizing the manufacturing cost of the object and / or the printing time of the manufactured object.

[0015] In a preferred extension of the method, optimizing the manufacturing schedule includes: The volume of the printhead is determined, wherein the volume determines the amount of printable material provided in each printing process; The geometric properties of the three-dimensional model are obtained, wherein the geometric properties can affect the component quality of the object; The segments are determined based on the three-dimensional model and the geometric properties; and Determine the filling process in the manufacturing plan.

[0016] Determining the volume of the printhead (wherein the volume determines the amount of printable material supplied in each printing process) is crucial for the further progress of the method, as it allows for the advantageous determination of the amount of printable material to be printed. The determined volume generates a dataset that can be stored on a data storage device and / or in the cloud, and can be used to optimize the manufacturing schedule.

[0017] Determining the geometric properties of the 3D model (wherein these properties define the characteristic properties of the object) provides data for optimizing the manufacturing plan. The provided data is part-specific and therefore can advantageously contribute to optimizing the method. The provided data generates a dataset that can be stored on a data storage device and / or in the cloud and can be used to optimize the manufacturing plan. Furthermore, this dataset can be provided in the source code of the algorithm used to create the manufacturing plan.

[0018] Based on the 3D model and its geometric properties, segments are determined, enabling the possible division of printing segments to optimize the manufacturing plan according to the part. These segments may also be referred to as blocks. The determination of segments generates a dataset that can be stored on a data storage device and / or in the cloud, and can be used to optimize the manufacturing plan.

[0019] Based on the preceding values ​​and data, the filling process is determined in the manufacturing plan. The filling process is then arranged into the manufacturing plan in an advantageous manner according to the component.

[0020] In an extended version of the method, a corresponding filling process is scheduled into the manufacturing plan before the printable material provided by each printing process, pre-given by the maximum volume of the print head, is emptied.

[0021] This avoids performing the filling process in locations detrimental to component quality, thereby improving component quality in a favorable manner.

[0022] In one extended scheme, the geometric properties are at least distinguished into visible and invisible regions of the object.

[0023] Invisible areas of an object include, for example, additionally generated discarded parts, support structures, structures between the object and the structural plates used to position the object, or infill structures inside the object's surface.

[0024] The visible area of ​​an object is, for example, the bottom side, top side, inner wall, or outer wall of the object.

[0025] The differentiation of geometric attributes can support decisions in a favorable manner for determining optimal manufacturing planning strategies.

[0026] In one extended approach, geometric properties are prioritized, and the infill process is scheduled into the manufacturing plan according to the priority. The infill process is preferably placed in an invisible region of the object. This advantageously shifts visible artifacts generated on the part by the process, reducing or eliminating their negative impact on part quality.

[0027] In one embodiment, the filling process in the manufacturing plan is arranged such that the printing process following the filling process preferably starts at the beginning of a new segment.

[0028] In a further embodiment, if the printing process following the filling process does not start at the beginning of the new segment, the filling process in the manufacturing plan can be arranged such that the subsequent printing process starts in an invisible area of ​​the object.

[0029] This invention also relates to a method for additively manufacturing an object using 3D printing. In this method, a three-dimensional model of the object is derived from at least one predetermined construction specification of the object and / or calculated photogrammetrically from multiple photographs of a three-dimensional sample of the object. Based on this three-dimensional model, a manufacturing plan for manufacturing the object is created using the previously described method. The manufacturing plan is then fed to a 3D printer. The 3D printer creates the object according to the manufacturing plan.

[0030] In this way, the total time required from creating construction specifications or from taking a photograph to completing the object can be significantly reduced. In particular, it increases the probability that the object will be successfully manufactured and will also perform its intended function, thus saving time and costs associated with failed attempts.

[0031] The method for creating the manufacturing plan is particularly implementable by a computer. Therefore, the invention also relates to a computer program having machine-readable instructions that, when executed on one or more computers, cause the one or more computers to perform the method for creating the manufacturing plan.

[0032] The computer program may include program code for configuring components, wherein, for example, parameters are provided for calculation: layer height, line width, support line width, fill line width, printhead speed, and force acting on the components. Thus, the computer program can calculate the optimal relationship between line width, line angle, fill method, etc., enabling the printing process to be performed in an optimal manner.

[0033] Similarly, the present invention also relates to a machine-readable data carrier or downloadable product having the computer program. A downloadable product is a digital product that can be transmitted via a data network (i.e., downloaded by a user of the data network), which may, for example, be available in an online store for immediate download.

[0034] In addition, the computer may be equipped with the computer program, machine-readable data carrier, or downloadable product.

[0035] Other improvements to the invention will be explained in more detail below with reference to the description of preferred embodiments of the invention and the accompanying drawings. Attached Figure Description

[0036] It shows: Figure 1 : A schematic illustration of a 3D printer 30 having a printhead 40; Figure 2 According to an embodiment of the method 100 of the present invention; Figure 3 Another embodiment of method 100; and Figure 4 : An embodiment of method 200. Detailed Implementation

[0037] Figure 1 A schematic illustration of a 3D printer 30 with a printhead 40 is shown, wherein the printhead 40 has a volume 41 and the volume 41 contains a certain amount of printable material 42 provided by the printhead 40 in each printing process. The printable material 42 is provided via a filling process (not shown), wherein the printhead interrupts the printing process during the filling process.

[0038] Figure 2 An embodiment of the method 100 according to the present invention is illustrated in the schematic flowchart, wherein the method 100 for creating a manufacturing plan 50 for an additively manufactured object 20 by means of 3D printing via at least one print head 40 of a 3D printer 30 comprises the following steps. In step 110, a three-dimensional model 21 of the object 20 to be manufactured is provided. In step 120, the manufacturing plan 50 is optimized such that the filling process 130 of the print head 40 is arranged in the manufacturing plan 50 according to the three-dimensional model 21 of the object 20.

[0039] Figure 3 Another embodiment of method 100 is shown, wherein optimizing the manufacturing plan 50 in 120 includes the following steps: The volume 41 of the printhead 40 is determined, wherein the volume 41 determines the amount of printable material 42 provided in each printing process; Determine the geometric properties 1, 2, ..., n of the three-dimensional model 21 described in 150, wherein the geometric properties 1, 2, ..., n can affect the component quality of the object 20; Based on the three-dimensional model 21 and the geometric attributes 1, 2, ..., n, the 160 segments B1, B2, ..., Bn are obtained; and Determine the filling process 130 in the manufacturing plan 50 described in 170.

[0040] The volume 41 of the printhead 40 may be constructed from a cavity and a piston that can move in the cavity, and the piston travels a piston stroke during the printing process, wherein the maximum volume 41 is proportional to the maximum piston stroke of the piston.

[0041] Within method 100, the corresponding filling process 130 is scheduled into manufacturing plan 50 before the printable material 42 provided by each printing process, pre-given by the maximum volume 41 or the maximum piston stroke of the print head 40, is emptied.

[0042] In addition, geometric attributes 1, 2, ..., n are divided into at least the visible and invisible regions of object 20, thereby enabling priority sorting of different geometric attributes.

[0043] The filling process 130 in the manufacturing plan 50 is arranged such that the printing process following the filling process 130 preferably starts at the beginning of the new segments B1, B2, ..., Bn. The segments B1, B2, ..., Bn or blocks are formed by the three-dimensional model 21 and the data of the corresponding geometric attributes 1, 2, ..., n, wherein each segment B1, B2, ..., Bn corresponds to a geometric attribute 1, 2, ..., n.

[0044] If the printing process following the filling process 130 cannot be initiated at the beginning of the new segments B1, B2, ..., Bn, then the filling process 130 in the manufacturing plan 50 is arranged such that the subsequent printing process is initiated within the invisible area of ​​the object 20. This arrangement in the manufacturing plan is made according to the priority order of geometric attributes 1, 2, ..., n.

[0045] Figure 4 An embodiment of method 200 is illustrated, wherein the embodiment is represented by a schematic flowchart. In step 210, a three-dimensional model 21 of the object 20 is obtained from at least one preset construction specification of the object 20 and / or calculated by photogrammetry from multiple photographs of a three-dimensional sample of the object 20. In step 220, based on the three-dimensional model 21, a manufacturing plan 50 for manufacturing the object 20 is created using the previously described method 100. In step 230, the manufacturing plan 50 is fed to a 3D printer 30. In step 240, the 3D printer 30 creates the object 20 according to the manufacturing plan 50.

Claims

1. A method (100) for creating a manufacturing plan (50) for an additively manufactured object (20) by means of 3D printing via at least one print head (40) of a 3D printer, the method comprising the steps of: - Provide (110) a three-dimensional model (21) of the object to be manufactured (20); and - Optimize (120) the manufacturing plan (50) such that the filling process (130) of the print head (40) is arranged in the manufacturing plan (50) according to the three-dimensional model (21) of the object (20).

2. The method (100) according to claim 1, characterized in that, Optimizing the manufacturing plan (50) as described in (120) includes: - Determine the volume (41) of the printhead (40) (140), wherein the volume (41) determines the amount of printable material (42) provided in each printing process; - Obtain the geometric properties (1, 2, ..., n) of the three-dimensional model (21) (150), wherein the geometric properties (1, 2, ..., n) can affect the component quality of the object (20); - Based on the three-dimensional model (21) and the geometric properties (1, 2, ..., n), the (160) segments (B1, B2, ..., Bn) are obtained; - Obtain the filling process (130) in the manufacturing plan (50) described in (170).

3. The method (100) according to claim 2, characterized in that, Before the printable material (42) provided by each printing process, which is pre-given by the maximum volume (41) of the print head (40), is emptied, the corresponding filling process (130) is scheduled into the manufacturing plan (50).

4. The method (100) according to any one of the preceding claims, characterized in that, The geometric attributes (1, 2, ..., n) are at least divided into visible and invisible regions of the object (20).

5. The method (100) according to any one of the preceding claims, characterized in that, The filling process (130) in the manufacturing plan (50) is arranged such that the printing process following the filling process (130) is preferably started at the beginning of the new segment (B1, B2, ..., Bn).

6. The method (100) according to any one of claims 1 to 4, characterized in that, If the printing process following the filling process (130) cannot be started at the beginning of the new segment (B1, B2, ..., Bn), the filling process (130) in the manufacturing plan (50) is arranged such that the subsequent printing process is started in the invisible area of ​​the object (20).

7. A method (200) for additive manufacturing of an object (20) using 3D printing, the method comprising the following steps: - Obtain (210) a three-dimensional model (21) of the object (20) from at least one preset construction specification of the object (20) and / or calculate (210) a three-dimensional model (21) of the object (20) by photogrammetry from multiple photographs of a three-dimensional sample of the object (20). - Based on the three-dimensional model (21), a manufacturing plan (50) for manufacturing the object (20) is created (220) using the method (100) according to any one of claims 1 to 6. - The manufacturing plan (50) is transmitted (230) to the 3D printer (30); - The object (20) is created (240) by the 3D printer (30) according to the manufacturing plan (50).

8. A computer program comprising machine-readable instructions that, when executed on one or more computers, cause the one or more computers to perform the method (100) according to any one of claims 1 to 6.

9. A machine-readable data carrier or downloadable product having the computer program according to claim 8.

10. A computer having a computer program according to claim 8 and / or a machine-readable data carrier and / or downloadable product according to claim 9.

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