GENERATIVE MANUFACTURING

Description

[0001] The present invention relates to additive manufacturing and in particular, but not exclusively, to automated post-processing of an additively manufactured polymer part.

[0002] Additive manufacturing (AM) is a process during which an object can be manufactured from a digital file using a layer-by-layer method without using a mould. Objects manufactured by this method usually require post-processing, including smoothing and colouring. This is particularly the case for AM polymer parts, which are generally used for aesthetic purposes. However, post-processing and inspection of AM parts is manually intensive and therefore currently accounts for the majority of the cost and time of conventional AM processes. This poses a barrier to the mass adoption of industrial AM and prevents it from competing with traditional centralised manufacturing industries.

[0003] A system and method for automated cleaning of parts produced by a three-dimensional object printer is described in US 2017 / 0239893 A1.

[0004] A surface treatment method for rapidly-manufactured three-dimensional objects is described in US 2008 / 0169585 A1, corresponding to the preamble of claim 1.

[0005] It is therefore an aim of certain embodiments of the present invention to provide a system and method for fully automating the AM process from initial part design to inspection of a post-processed AM part.

[0006] It is an aim of certain embodiments of the present invention to provide a modular end-to-end automated post-processing manufacturing system and method for fully automating the AM process which can be applied to many consumer and high value businesses creating flexibility and allowing the full exploitation of AM.

[0007] It is an aim of certain embodiments of the present invention to provide a system and method for fully automating the AM process which is customisable to provide flexibility to a user in terms of post-processing and inspection of AM parts.

[0008] According to a first aspect of the present invention, there is provided a system for automatically processing an additively manufactured part, comprising: a de-powdering module for removing un-processed support powder surrounding an additively manufactured part; an optical inspection module for optically determining at least one part parameter associated with a surface finish of the additively manufactured part, wherein the at least one part parameter is a surface texture of the additively manufactured part; a processing module for processing a surface of the additively manufactured part responsive to the at least one part parameter determined by the optical inspection module; and a controller configured to modify a processing parameter of a surface finishing process, performed by the processing module, based on the at least one part parameter determined by the optical inspection module.

[0009] Advantageously, the system of the first aspect of the invention is able to provide a fully automated AM process, thereby improving system throughput.

[0010] Optionally, the system comprises at least one conveyor configured to move the additively manufactured part from an additive manufacturing apparatus to the de-powdering module.

[0011] Advantageously, this reduces the burden placed on an operator when post-processing a part, thereby helping to improve the throughput of the system.

[0012] Optionally, the de-powdering module comprises a plurality of de-powdering modules each configured for removing a different grade of powder from the part.

[0013] Optionally, the optical inspection module may be a non-contact optical inspection module.

[0014] Advantageously, this helps to reduce the likelihood of the optical inspection module causing damage to the AM part during inspection.

[0015] Optionally, the de-powdering module comprises a fluidising bed reactor.

[0016] Advantageously, this feature enables courser powders to be removed efficiently.

[0017] Optionally, the de-powdering module is configured to impart ultrasonic waves in a water-surfactant solution.

[0018] Advantageously, the feature enables the removal of finer powders from the AM part.

[0019] Optionally, the system comprises at least one support collection module for collecting support material removed from the part.

[0020] Advantageously, this helps to reduce wastage when using the system.

[0021] Optionally, the support collection module comprises at least one powder recovery module for recovering unprocessed powder removed from the part.

[0022] Advantageously, this enables recycling of powder from the system, thereby further reducing wastage.

[0023] Optionally, the at least one conveyor comprises at least one conveyor belt for transporting the part from the de-powdering module to the processing module.

[0024] Advantageously, the conveyor belt provides a stable platform to enable processes to be performed whilst the part is being moved, thereby improving throughput of the system.

[0025] Optionally, the optical inspection module is configured to determine the at least one part parameter associated with a surface finish of the part whilst the part is being transported on the at least one conveyor.

[0026] Advantageously, this removes the need for separate measuring and conveyance steps to be performed by the system, and hence overall throughput can be further improved.

[0027] Optionally, the at least one conveyor comprises at least one robotic arm.

[0028] Advantageously, this enables AM parts to be directly placed within each of the respective modules, which helps to further improve system throughput and also provides a space-saving benefit since the need for intricate conveyance paths between modules can be avoided.

[0029] Optionally, the at least one robotic arm comprises a robotic arm configured to locate the part on a support of the processing module.

[0030] Optionally, the or a further robotic arm is configured to load and unload the support into and from the processing module.

[0031] Optionally, the processing module is configured to smooth a surface of the part responsive to the at least one part parameter associated with a surface finish of the part.

[0032] Advantageously, this enables parts processed by the system to exhibit skin-touch friendly and low friction characteristics.

[0033] Optionally, the processing module comprises: a reservoir for containing a liquid solvent; and a processing chamber in controllable fluid communication with the reservoir.

[0034] Optionally, the processing module comprises a solvent delivery system configured to receive a predetermined amount of solvent from the reservoir and introduce the same into the processing chamber.

[0035] Advantageously, this enables AM parts with intricate geometries to be more easily processed.

[0036] Optionally, the solvent delivery system is configured to controllably heat the solvent to a predetermined solvent temperature to cause the same to vaporise.

[0037] Optionally, the system comprises at least one additive manufacturing apparatus.

[0038] Optionally, the de-powdering module may comprise a cooling chamber, and a sensor configured to monitor a temperature of the cooling chamber.

[0039] The controller may be configured to receive feedback from the sensor and produce an output for adjusting a print procedure of an additive manufacturing apparatus based on the feedback received from the sensor.

[0040] Advantageously, this helps to reduce cooling times, and hence system processing times, thereby further improving system throughput.

[0041] Optionally the controller may be configured to modify a de-powdering process parameter of a de-powdering process, performed by the de-powdering module, based on the at least one part parameter determined by the optical inspection module.

[0042] Advantageously, this helps to improve the efficiency of support removal and helps to optimise the post-processing steps to improve system throughput.

[0043] Optionally, the optical inspection module may be configured to analyse the at least one part parameter after the surface of the part has been processed by the processing module.

[0044] The controller may be configured to further modify the processing parameter of the surface finishing process, performed by the processing module, based on the at least one part parameter determined by the optical inspection module after the surface of the part has been processed by the processing module.

[0045] Advantageously, this helps to improve the surface finish quality of parts processed using the system.

[0046] Furthermore, since the system automatically adjusts the surface finishing processing parameters in response to a part falling below a desired surface finish quality, the amount of waste or "dud" parts produced using the system is also reduced.

[0047] Optionally, the controller may be configured to modify a processing parameter of a surface finishing process for processing a new part, based on the at least one part parameter determined by the optical inspection module.

[0048] Advantageously, this helps to efficiently ensure than any future parts manufactured by the system meet the required quality standards, without any further operator input being required.

[0049] Optionally, the system may comprise at least one conveyor for locating the part in the de-powdering module (108) and moving the part between the modules.

[0050] According to a second aspect of the present invention there is provided a method of automatically processing an additively manufactured part, comprising: providing an additively manufactured part; by a de-powdering module (108), removing unprocessed support powder surrounding the additively manufactured part; by an optical inspection module, optically determining at least one part parameter associated with a surface finish of the additively manufactured part, wherein the at least one part parameter is a surface texture of the additively manufactured part; by a controller, modifying a processing parameter of a surface finishing process, performed by a processing module, based on the at least one part parameter determined by the optical inspection module; and by the processing module, processing a surface of the additively manufactured part responsive to the at least one part parameter.

[0051] Advantageously, as with the first aspect of the present invention, since the system is able to automatically analyse and accordingly process AM parts, the overall burden placed on the system operator can be drastically reduced, and hence, product throughput can be drastically improved as a result.

[0052] Optionally, the optical inspection module may be configured to analyse the at least one part parameter after the surface of the part has been processed by the processing module.

[0053] The controller may be configured to further modify the processing parameter of the surface finishing process, performed by the processing module, based on the at least one part parameter determined by the optical inspection module after the surface of the part has been processed by the processing module.

[0054] Advantageously, this helps to improve the surface finish quality of parts processed using the system.

[0055] Furthermore, since the system automatically adjusts the surface finishing process parameters in response to a part falling below a desired surface finish quality, the amount of waste or "dud" parts produced using the system is also reduced.

[0056] Optionally, the method may comprise, by an additive manufacturing apparatus, manufacturing a part.

[0057] Optionally, the method may comprise, by a cooling chamber, cooling the manufactured part, by a sensor, monitoring a temperature of the cooling chamber, and, by the controller, receiving feedback from the sensor and producing an output for adjusting a print procedure of an additive manufacturing apparatus based on the feedback received from the sensor.

[0058] Advantageously, this helps to reduce cooling times, and hence system processing times, thereby further improving system throughput.

[0059] Optionally, the method comprises, by the controller, modifying a de-powdering process parameter of a de-powdering process, performed by the de-powdering module, based on the at least one part parameter determined by the optical inspection module.

[0060] Optionally, the method comprises, by a conveyor, moving the part from an additive manufacturing apparatus to the de-powdering module.

[0061] Optionally, the method comprises, by the processing module, smoothing a surface of the part responsive to the at least one part parameter associated with a surface finish of the part.

[0062] Optionally, the method may comprise, by a controller, modifying a processing parameter of a surface finishing process for processing a new part, based on the at least one part parameter determined by the optical inspection module.

[0063] Advantageously, this helps to efficiently ensure than any future parts manufactured by the system meet the required quality standards, without any further operator input being required.Description of the Drawings

[0064] Certain embodiments of the present invention will now be described with reference to the accompanying drawings in which: Figure 1 illustrates a digital manufacturing system according to certain embodiments of the present invention; and Figure 2 illustrates a digital manufacturing method according to certain embodiments of the present invention. Detailed Description

[0065] As illustrated in Figure 1, a digital manufacturing system 100 includes a controller 102, e.g. a computer, connected by wire or wirelessly to one or more 3D printers 104 for additively manufacturing at least one AM part. The controller 102 is configured to receive data, for example CAD data, relating to the 3D part / s to be printed. The data, e.g. an STL file including part requirements (e.g. dimensional tolerances, geometrical tolerances, surface texture, surface roughness, and colour), is sent to the 3D printer / s via suitable 3D printer software. The 3D printer / s 104 may be the same or a combination of different AM printers from the same or different manufacturers each suitable for printing a 3D part using an AM technique, including Selective Laser Sintering (SLS), Multi Jet Fusion (MJF), High Speed Sintering (HSS), Fused Filament Fabrication or Fused Deposition Modelling (FFF / FDM) or Stereolithography (SLA), or the like.

[0066] A robotic system 106 is configured to retrieve one or more 3D printed powder blocks, including one or more AM parts therein, from at least one of the printers 104 and transport them to a support removal module 108.

[0067] The support removal module 108 includes a cooling chamber to cool down an as-printed powder cake of AM parts to a temperature suitable for de-powdering. The cooling chamber is aptly configured to control the temperature of the cooling chamber surfaces and interior, and aptly includes at least one thermocouple to monitor the ambient temperature within the cooling chamber.

[0068] A pump may be provided to flood the cooling chamber with an inert gas and a vacuum pump may be provided to remove the inert gas from the cooling chamber.

[0069] At least one heat exchanger may be provided to control the temperature of the cooling chamber.

[0070] The as-printed cake including one or more AM parts may be located in the cooling chamber by a robotic actuator of the robotic system 106, e.g. transported automatically and in a controlled manner from a printing / processing chamber of one of the 3D printers 104 to the cooling chamber.

[0071] The support removal module 108 is configured to remove unprocessed powder surrounding the AM part. The module may include a de-powdering chamber which is separate to the cooling chamber or the cooling chamber may be configured to be a de-powdering chamber. The de-powdering chamber may aptly include a fluidising bed reactor to remove the powder from the AM part by fluidising loose powder and separating it from the solid AM part. The fluidising bed reactor comprises a gas inlet, distributor, and gas outlet.

[0072] Alternatively, the de-powdering chamber may comprise a sieve shaker with an ultrasonic vibrating device to vigorously agitate the AM part / s and remove the bulk of un-sintered powder therefrom. The sieve may comprise a stainless-steel mesh with a pore size larger than the diameter of the polymer powder particles, and the vibrating device may comprise an array of ultrasonic transducers. The removed un-sintered powder may be collected beneath the fluidisation chamber or sieve shaker in a powder collection chamber of a powder recovery module 110.

[0073] Optionally, the AM part / s may be automatically transferred by the or a further robotic system to one or more additional de-powdering chambers 112a, 112b for further de-powdering, e.g. medium and fine grade de-powdering and / or half-sintered powder which is unsuitable for recycling. The additional de-powdering chamber / s 112 may also include a sieve shaker and ultrasonic vibrating device or may include other suitable de-powdering means such as a de-powdering module configured to impart ultrasonic waves in a water-surfactant solution, such as described in GB1808639.7 by Additive Manufacturing Technologies Limited. The recovered powder can be disposed via the same powder recovery module 110 or a different powder recovery module / s 114.

[0074] The system 100 includes at least one first conveyor 116, e.g. belt, for transporting 'unprocessed' AM parts from the de-powdering modules 108,112a, 112b towards a surface finishing module / apparatus 118.

[0075] An optical inspection module 120 is also provided to identify a surface texture of each AM part on the first conveyor 116, corresponding to a surface finish quality of the part before post-processing. The inspection module 120 is also configured to provide data relating to the surface finish quality of the part to the controller 102. The controller 102 is configured to then operate the surface finishing module / apparatus 118 accordingly to achieve a desired surface texture. A suitable inspection module 120 is described in GB 2572953 by Additive Manufacturing Technologies Limited.

[0076] In other embodiments, the controller 102 may be configured to modify parameters of the de-powdering process, performed by the de-powdering module 108, based on the surface texture identified by the optical inspection module 120. This helps to remove the supports of the part in a more efficient way to ensure as much of the support as possible is removed. Also it helps to reduce the amount of surface processing that is required by the surface finishing module 118, thereby helping to further improve product throughput.

[0077] The system 100 includes at least one first robotic arm 122 with object recognition / vision capability for automatically identifying an AM part / s on the first conveyor 116 and locating / retrieving the same onto / from a rack / hanger of the surface finishing module / apparatus 118. At least one further robotic arm 124 may be provided with object recognition / vision capability for automatically locating / retrieving each rack / hanger into / from the surface finishing module / apparatus 118. Aptly, the first and further robotic arms 122,124 may be provided by the same unit.

[0078] The surface finishing module / apparatus 118 is aptly configured to automatically smooth an AM polymer part to a desired surface roughness by using a solvent-based method, such as described in GB 2560073 by Additive Manufacturing Technologies Limited. The surface finishing module / apparatus 118 is also aptly configured to automatically colour an AM polymer part using a suitable colouring method, such as described in GB 2571804 by Additive Manufacturing Technologies Limited.

[0079] Once the AM part / s has been processed as desired, it is removed from the surface finishing module / apparatus 118 by the robotic arm / s 122,124 and placed on a second conveyor 126, e.g. belt.

[0080] The optical inspection module 120 is configured to re-identify the surface texture of the AM part, after it has been processed by the surface finishing module 118, to determine the surface finish quality of the processed AM part / s. If the AM part fails to meet a desired surface finish quality, the part is reprocessed or discarded as required. The empty racks are retrieved from the second conveyor. Post-processed AM parts which meet the desired surface finish quality (i.e. a desired smoothness and / or colour) are removed from the second conveyor by the robotic arm / s for packaging and shipping.

[0081] The optical inspection module 120 is configured to feed back the surface finish quality of the identified post-processed part to the controller 102. In turn, the controller 102 is configured to adjust parameters of the surface finishing process, performed by the surface finishing module 118, accordingly to help ensure that any further parts being manufactured and post-processed by the system achieve the desired surface finish quality.

[0082] The individual processes and modules of the system 100 are linked and selectively controlled by a software application executed by the controller 102 which automatically manages the AM process and links the system 100 to the 3D printers and the initial CAD stage.

[0083] A digital manufacturing method 200 according to certain embodiments of the present invention will now be described with reference to Figure 2.

[0084] At step 202, a powder cake / block containing one or more AM parts has been manufactured using one of the 3D printers 104.

[0085] At step 204, the AM block is transferred by the robotic system 106, e.g. a robotic arm, to the cooling and de-powdering module 106 and cooled to a desired temperature for de-powdering. Once the AM block is cooled to around 100°C or less, it is transferred to the de-powdering module 108 by the robotic system 106.

[0086] To decrease the cooling time, the controller 102 is configured to the adjust the print procedures of the 3D printers 104 based on the temperature of the cooling chamber to allow for more rapid cooling of the chamber and hence improved processing times.

[0087] At step 206, the AM block is broken down and the AM parts within the block are de-powdered by the de-powdering module / s. The support removing module may in addition to or as an alternative to the de-powdering module.

[0088] At step 208, the powder from the AM parts is recovered using the powder recovery module / s 110,114. The recovered powder is aptly sorted into un-sintered re-usable powder and non-reusable waste powder. In the meantime, the de-powdered AM parts are transferred onto the first conveyor 116.

[0089] At step 210, while on the first conveyor 116, the surface of the de-powdered AM part / s is analysed using the non-contact optical inspection module 120. The inspection module 120 analyses the surface texture, colour, and part geometry and sends the information to the controller 102 which in turn sends appropriate parameters to the surface finishing module 118.

[0090] In other embodiments, the controller 102 may further modify parameters of the de-powdering process, performed by the de-powdering module 108, based on the analysis of the non-contact optical inspection module 120. This helps to improve the quality of support removing and reduce the amount of post-processing that is required at the surface finishing module 118.

[0091] The AM parts are then transferred further along the first conveyor 116 towards the first robotic arm 122 which identifies the parts and hangs them onto a rack / hanger / frame support for loading into the surface finishing module 118.

[0092] At step 212, the AM parts undergo the desired surface processing, including smoothing and / or colouring before being removed from the surface finishing module 118 by the second robotic arm 124 and placed on the second conveyor 126. The processed AM parts are removed from the rack / hanger by the first robotic arm 122.

[0093] At step 214, the surface of the processed AM parts is re-analysed by the non-contact optical inspection module 120. The inspection module 120 feeds back the determined surface quality to the controller 102. Any AM parts that do not meet a predetermined quality criteria and which can no longer be improved via reprocessing are discarded for recycling. The controller 102 then adjusts parameters of the surface finishing process, performed by the surface finishing module 118, based upon the inspection module 120 feedback so that any future parts processed by the system are able to meet the desired surface quality criteria.

[0094] This helps to ensure that any further parts processed using the system meet the predetermined quality criteria, which helps to reduce the amount of "dud" parts processed via the system.

[0095] At step 218, the finished and acceptable AM parts are manually or robotically removed from the second conveyor to be packaged / shipped.

[0096] The afore-described system and method are therefore able to digitally post-process and handling unique 3D printed components, without requiring burdensome operator input for the processing of each part, thereby removing the operator from the process.

[0097] Furthermore, by using an iterative feedback approach, the system can generate special sets of parameters for each unique 3D printed part for each post-processing step, without any need of human supervision, to help efficiently ensure that any future parts manufactured using the system meet desired surface quality criteria.

[0098] Certain embodiments of the present invention therefore provide a system and method for fully automating the AM process from initial part design to inspection of a post-processed AM part. The present invention provides a flexible and customisable modular end-to-end automated post-processing manufacturing system and method for fully automating the AM process which can be used for many different consumer and industrial applications.

[0099] In exemplary embodiments, the support removal process and processing step may be performed as a single step e.g. by the system including a single processing module for processing a surface of the part responsive to the at least one part parameter and a controller configured to modify a processing parameter of a surface finishing process, performed by the processing module, based on the at least one part parameter determined by the inspection module.

Claims

1. A system (100) for automatically processing an additively manufactured part, comprising: a de-powdering module (108) for removing un-processed support powder surrounding an additively manufactured part; an optical inspection module (120) for optically determining at least one part parameter associated with a surface finish of the additively manufactured part, wherein the at least one part parameter is a surface texture of the additively manufactured part; a processing module (118) for processing a surface of the additively manufactured part responsive to the at least one part parameter determined by the optical inspection module; characterised by a controller (102) configured to modify a processing parameter of a surface finishing process, performed by the processing module (118), based on the at least one part parameter determined by the optical inspection module (120).

2. The system (100) according to claim 1, wherein the de-powdering module (108) comprises a cooling chamber, and a sensor configured to monitor a temperature of the cooling chamber, and wherein the controller (102) is configured to receive feedback from the sensor and produce an output for adjusting a print procedure of an additive manufacturing apparatus (104) based on the feedback received from the sensor.

3. The system (100) according to claim 1 or claim 2, wherein the controller (102) is further configured to modify a de-powdering process parameter of a de-powdering process, performed by the de-powdering module (118), based on the at least one part parameter determined by the optical inspection module (120).

4. The system (100) according to any preceding claim, wherein the controller (102) is configured to modify a processing parameter of a surface finishing process for processing a new part, based on the at least one part parameter determined by the optical inspection module (120).

5. The system (100) according to any preceding claim, wherein the de-powdering module comprises a plurality of de-powdering modules (112a, 112b) each configured to remove a different grade of powder from the part.

6. The system (100) according to claim 5, wherein the de-powdering module comprises a fluidising bed reactor and / or wherein the de-powdering module is configured to impart ultrasonic waves in a water-surfactant solution.

7. The system (100) according to any preceding claim, wherein the processing module (118) is configured to smooth a surface of the additively manufactured part responsive to the at least one part parameter associated with a surface finish of the part.

8. The system (100) according to any preceding claim, wherein the system (100) comprises a conveyor (116) for transporting the additively manufactured part from the de-powdering module (108) towards the processing module (118).

9. The system (100) according to claim 8, wherein the system (100) comprises a robotic arm (122) configured for automatically identifying additively manufactured parts on the conveyor (116) and locating said additively manufactured parts on a support of the processing module (118).

10. The system (100) according to claim 8 or claim 9, wherein the optical inspection module (120) is configured to determine the at least one part parameter associated with a surface finish of the additively manufactured part whilst the part is being transported on the conveyor (116).

11. A method of automatically processing an additively manufactured part, comprising: providing an additively manufactured part; by a de-powdering module (108), removing unprocessed support powder surrounding the additively manufactured part; by an optical inspection module (120), optically determining at least one part parameter associated with a surface finish of the additively manufactured part, wherein the at least one part parameter is a surface texture of the additively manufactured part; by a controller (102), modifying a processing parameter of a surface finishing process, performed by a processing module (118), based on the at least one part parameter determined by the optical inspection module (120); and by the processing module (118), processing a surface of the additively manufactured part responsive to the at least one part parameter.

12. The method according to claim 11, further comprising the steps of: by a cooling chamber, cooling the additively manufactured part; by a sensor, monitoring a temperature of the cooling chamber; and by the controller (102), receiving feedback from the sensor and producing an output for adjusting a print procedure of an additive manufacturing apparatus based on the feedback received from the sensor.

13. The method according to claims 11 or 12, comprising, by the processing module (118), smoothing a surface of the additively manufactured part responsive to the at least one part parameter associated with a surface finish of the part.

14. The method according to any of claims 11 to 13, comprising, by the controller (102), modifying a processing parameter of a surface finishing process for processing a new part, based on the at least one part parameter determined by the optical inspection module.

15. The method according to any of claims 11 to 14, comprising, by a conveyor (126), moving the additively manufactured part from the de-powdering module (108) towards the processing module (118).