Determining the properties of components manufactured by powder bed fusion additive manufacturing

Abstract

Determining the properties of components manufactured by powder bed fusion additive manufacturing A method of manufacturing a component is disclosed, wherein each component of a batch of components is assigned a respective unique identifier. The batch of components is manufactured using a Powder Bed Fused Additive Manufacturing (PBFAM) system, wherein each component of the batch of components includes a respective unique identifier. Each unique identifier can be used to provide a comprehensive understanding of the component.

Description

[Technical Field]

[0001] The present invention relates to determining properties of manufactured components. The properties include information about the component and manufacturing properties. Knowledge of the properties can be used to improve the component. [Background technology]

[0002] The Powder Bed Fused Additive Manufacturing (PBFAM) process is well known. Typically, a PBFAM process begins with a 3D CAD model of a component. Appropriate software slices the 3D CAD model into individual layers, which can be thought of as a series of cross sections of the component. The PBFAM process manufactures the component layer by layer, with each layer corresponding to a separate layer (or cross section). Each layer is formed from powder that is spread onto a build platform within the build volume of the PBFAM system. An energy source, such as a thermal print head, laser, infrared source, or electron beam, is used to sinter, fuse, or melt the powder to create the current layer. This means that each layer contains both unaltered powder and powder that has been transformed to form the current layer. Once the current layer is formed, the process is repeated, with a new layer being formed on the previous layer, until all the individual layers (or cross sections) that define the component have been formed.

[0003] An exemplary PBFAM process and associated system 100 is shown in FIG. 1. As the current layer is produced by a heat source, laser, or electron beam acting on powder (i.e., energy source 110), a build platform 120 is lowered a distance corresponding to the thickness of the individual layer. A roller or blade 130 is used to apply a new layer of powder 140 on top of the previous layer. The new layer of powder is provided by raising platform 150. The heat source, laser, or electron beam then acts on the new layer of powder to form the new layer on top of the previous layer. This process continues until component 160 is formed. As shown in FIG. 1, build volume 170 contains the manufactured component 160 and unfused, unsintered, or unmelted powder (i.e., unaltered powder) 180. This unaltered powder is removed during post-processing operations to obtain the component.

[0004] Typical powder materials include plastics such as nylon, metals such as aluminum, and alloys such as titanium-based alloys. Known PBFAM processes include selective laser sintering (SLS), selective laser melting (SLM), direct laser sintering (DMLS), electron beam melting (EBM), and multi-jet melting (MJF).

[0005] Typically, millions of components are manufactured for a common application, such as building a particular system. While it may be possible to distinguish one component from another by visual inspection when the components are different, this is impractical when the number of components is large. Even if components can be distinguished in this way, a group of components that are identical in appearance and configuration may have different uses or be manufactured using different processes. Given the number of different processes available, it may be difficult to determine component information and / or how it was manufactured from inspecting the component itself. In other words, components that appear identical may actually differ in terms of use / placement and / or manufacturing.

[0006] While each component can be labeled immediately after production, such a process is inefficient. For example, each individual label must be manually recorded against component data, including manufacturing data such as the type of PBFAM process used. During a typical PBFAM process, appropriate settings are used for the PBFAM system. The PBFAM system can also monitor the process and generate real-time data. However, neither the settings nor the real-time data are used beyond the operation of the PBFAM system itself. Nevertheless, the settings and real-time data can be useful when associated with a component. When the number of components produced is large, recording such information is particularly tedious and error-prone. Even if the manufacturing properties of each component were recorded in this manner, the ability to record specific manufacturing properties is still lost.

[0007] One such example is when several identical components are fabricated within a build volume. The process by which components are placed / formed within the build volume can be controlled by a nesting algorithm. The goal of the nesting algorithm is to optimize the use of space within the build volume, which saves costs and increases productivity. In particular, as much of the available space within the build volume as possible should be used for components. In other words, the amount of unconverted powder within the build volume should be minimized. The nesting algorithm analyzes the 3D CAD models of the components and positions and orients them to maximize the number of components that can be obtained from the build volume. The nesting algorithm software can be fully automated, manual, or a combination thereof.

[0008] As mentioned above, the unchanged powder must be removed in a post-processing step to obtain components. The post-processing step involves an operator manually dividing the build volume to obtain components and remove as much powder as possible. When a build volume is used to manufacture a large number of identical components (e.g., at least 100), it is impossible to track where each component originated within the build volume. For example, during post-processing, the build volume may disintegrate in an unpredictable manner, resulting in components in an order that bears little or no resemblance to their arrangement within the build volume. Figure 2 shows such a build volume 270 with 27 components 260. During post-processing, groups of components may collapse together and then disintegrate before they could otherwise be removed. During post-processing, the task of labeling the original order / arrangement of components, as set by the nesting algorithm, is similar to trying to identify where the building blocks of a demolished high-rise building were located within the high-rise building.

[0009] Knowing the configuration of the PBFAM system and / or where components are located and therefore formed within the build volume is useful when evaluating the performance or quality of a component. If a particular component is shown to be suboptimal or fails in a consistent manner, it may be possible to improve the performance or quality of this component when subsequently manufactured by changing the PBFAM system settings and / or the location / orientation of the component within the build volume.

[0010] Generally, there is a need to determine information including manufacturing properties of components produced by a PBFAM system, to use the determined manufacturing properties to improve the quality of components produced by subsequent PBFAM systems, and to easily access information including the manufacturing properties of components using a database.

[0011] Such components can be used in load handling devices such as those described in UK Patent Application No. GB2520104A (Ocado Innovation Limited). Load handling devices are automated systems with moving components / parts. Having detailed information about all the components / parts can help optimize the operation of the load handling device. Summary of the Invention

[0012] In one aspect, there is a method for manufacturing a component, the method comprising: assigning a respective unique identifier to each respective component of the batch of components; and manufacturing a batch of components using a Powder Bed Fused Additive Manufacturing (PBFAM) system, wherein each component of the batch of components is provided with a unique identifier, meaning that any one isolated component can be distinguished from any other component in the batch.

[0013] The method may further comprise interfacing with and updating a nesting file to manufacture each component of the batch of components with a respective unique identifier, meaning that the above aspects can be easily integrated into existing manufacturing processes.

[0014] Each respective unique identifier can indicate at least one property of each component of a batch of components, which means that each unique identifier can go beyond simply identifying a component.

[0015] The at least one property may include a manufacturing property, meaning that each component may be distinguished by the manufacturing process used.

[0016] The at least one manufacturing property can comprise at least one of: a respective location of each component of a batch of components within a build volume of the PBFAM system, a powder bed temperature setting of the PBFAM system, an energy source setting of the PBFAM system, a powder diffusion rate of the PBFAM system, an inkjet array setting of the PBFAM system, at least one material used in the PBFAM system, a model of the PBFAM system, a job number of the PBFAM system, a batch number of the batch of components, a material from which the component is manufactured, and a time and / or duration of manufacture of the batch of components. This means that each component can be distinguished by the exact manufacturing process used.

[0017] The method may further comprise interfacing with a nesting algorithm to receive the respective positions within the build volume, meaning that the exact positions of the components during the manufacturing process are known and recorded.

[0018] The method can further comprise interfacing with the PBFAM system to receive at least one of a powder bed temperature setting for the PBFAM system, an energy source setting for the PBFAM system, a powder application rate for the PBFAM system, and an inkjet array setting for the PBFAM system, meaning that the exact parameters / settings of the PBFAM system used during the manufacturing process are known and recorded.

[0019] At least one of the PBFAM system powder bed temperature settings, the PBFAM system energy source settings, the PBFAM system powder diffusion rate, and the PBFAM system inkjet array settings can be received in real time as the component is manufactured, meaning that any variations in the parameters / settings used during the manufacturing process are known and recorded.

[0020] The at least one property may comprise information comprising at least one of a design of the component, a description of the component, installation instructions for the component, a system in which the component is used, a revision number of the component, compatibility of the component with other components or systems in which the component is used, geometric dimension and tolerance data of the component, and a location in a load handling device in which the component is used, which means that each component may be distinguished by its use.

[0021] The method may further comprise mapping at least one property to a respective unique identifier of each component and indicating the at least one property of each component using the mapping. The method may further comprise storing the respective unique identifier of each component, the at least one property, and the mapping in a database. This means that a comprehensive understanding of each component can be provided.

[0022] The method may further comprise determining performance of at least one component of the batch of components, and upon determining that the performance of the at least one component can be improved, determining at least one property of the component using a unique identifier of the at least one component, modifying the at least one property of the component to improve performance, and manufacturing the component having the modified at least one property. Manufacturing the component having the modified at least one property may comprise manufacturing the component as part of a subsequent batch of components using the PBFAM system, meaning that the next version of the component will have improved performance compared to the components of the batch of components.

[0023] At least one property of the components of the batch of components can comprise a mechanical property comprising a respective position within a build volume of a PBFAM system that produced the batch of components, and modifying at least one property of the components of a subsequent batch of components can comprise modifying the respective position within a build volume of a PBFAM system that produces the subsequent batch of components, meaning that defects due to component orientation / position can be corrected.

[0024] The method may further comprise interfacing with a nesting algorithm to correct the respective positions within the build volume of the PBFAM system that produces the subsequent batch of components, meaning that the components are free of orientation / positional defects.

[0025] Modifying each position can comprise at least one of constraining the rotational degrees of freedom of each component, prioritizing components, defining no-build zones to ensure minimum spacing between parts, forming sacrificial cases / covers to group and / or protect certain components, changing the total number of components in the build volume, and changing the thickness of each PBFAM layer used to form the components in the PBFAM system. This means that the build volume can be optimized with respect to improving the quality of all components manufactured therein.

[0026] At least one property of the components of the batch of components can comprise a mechanical property comprising at least one of a powder bed temperature setting of the PBFAM system, an energy source setting of the PBFAM system, a powder diffusion rate in the PBFAM system, and an inkjet array setting of the PBFAM system, and modifying at least one property of the components of the subsequent batch of components can comprise modifying at least one of a powder bed temperature setting of the PBFAM system producing the subsequent batch of components, an energy source setting of the PBFAM system producing the subsequent batch of components, a powder diffusion rate in the PBFAM system producing the subsequent batch of components, and an inkjet array setting of the PBFAM system producing the subsequent batch of components. This means that the PBFAM manufacturing process can be precisely tuned to improve component performance.

[0027] The method may further comprise assigning a respective unique identifier to the component, or each respective component of a subsequent batch of components, meaning that any one isolated component can be distinguished from any other component in a subsequent batch.

[0028] Each respective identifier can indicate at least one property of a respective component of a subsequent batch of components, and each component of a subsequent batch of components comprises a respective unique identifier, which means that each unique identifier can go beyond simply identifying a component.

[0029] The method may further comprise determining whether at least one component of the plurality of components has similar or identical properties to the component determined to be capable of improving performance, and upon determining that at least one component of the plurality of components has similar or identical properties to the component determined to be capable of improving performance, providing a respective unique identifier for the or each component of the plurality of components, which means that the components can be pre-identified, invoked, and / or modified as needed.

[0030] The unique identifier indicates a characteristic of the component, or manufacturing a batch of components further comprises forming at least one characteristic identifier on the component, which means that a user can decide how to use and / or install the component.

[0031] Each respective identifier may be formed by embossing or debossing on each respective component, or at least one characteristic identifier may be formed by embossing or debossing on each respective component, meaning that the identifier persists even in the presence of wear.

[0032] Each component in a batch of components has its own unique identifier on a designated area of ​​the component, which means that the unique identifier does not affect the component.

[0033] In another aspect, there is a computer program product comprising instructions that, when executed by a computer, cause the computer to carry out the method of any of the above aspects.

[0034] In another aspect, there is a data processing system comprising a processor configured to perform the method of any of the above aspects.

[0035] The present invention will now be described with reference to one or more exemplary embodiments thereof as illustrated in the accompanying drawings. [Brief explanation of the drawings]

[0036] [Figure 1] Figure 1 shows a powder-based fused deposition modeling system. [Figure 2] FIG. 2 shows a build volume with multiple components. [Figure 3] FIG. 3 illustrates a method for manufacturing a component according to the invention. [Figure 4] FIG. 4 illustrates components with unique identifiers according to the present invention. [Figure 5] FIG. 5 illustrates a system for performing the method of FIG. [Figure 6] FIG. 6 illustrates a method for improving the performance of a component according to the present invention. [Figure 7] FIG. 7 illustrates a method for identifying a component among a plurality of components whose performance can be improved in accordance with the present invention. [Figure 8] FIG. 8 illustrates a method for searching a database according to the present invention. [Figure 9] FIG. 9 illustrates a user interface / front end that may be used with the method of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0037] 3 shows steps of a method 300 for manufacturing components. In step 310, a unique respective identifier is assigned to each component of a batch of components. A batch of components is components that are produced simultaneously using the PBFAM system. The components may be different, similar / identical, or a combination thereof (e.g., a first set of similar / identical components and a second set of different components). The total number of components varies depending on the size of the components and the build volume. Thus, components, when manufactured together in the PBFAM system, are considered to form a batch of components, regardless of the type or number of components.

[0038] Advantageously, each unique identifier can be used to uniquely identify the component with which it is associated. An example of each identifier includes a string of characters. The number of characters in the string can be set depending on the number of components to be manufactured. Additionally / alternatively, a type symbol may be used. Another example is a 3D Quick Response (QR) code or a barcode.

[0039] In step 320, a batch of components is manufactured using the PBFAM system. Each component is manufactured to include its respective identifier. In this way, each component has a permanent display of its respective unique identifier. The respective unique identifier may be included, for example, by embossing or debossing, which ensures that the identifier persists even if the component is subjected to wear. Debossing may be preferred when the outer contour of the component cannot accommodate the additional height resulting from embossing. Embossing may be preferred when the material removal resulting from debossing may adversely affect the performance of the component. Each component in the batch of components can be uniquely identified based on its respective identifier, even if the components are otherwise identical in appearance and configuration. Furthermore, when several batches of components are produced using the method of FIG. 3, each component can be uniquely identified. That is, the unique identifier is unique across all batches produced using the method of FIG. 3. In other words, the unique identifier is not duplicated, and all components produced using the method of FIG. 3, not just the current batch, will have a unique identifier. An example of a component created according to the process of Figure 3 is shown in Figure 4. Component 400 has a unique identifier 410 within a designated area 420.

[0040] The method of Figure 3 has several advantages. As described below, the unique identifier can be used to identify at least one property, such as specific information about the use or manufacturing properties of the component. This is particularly useful when mass-produced systems incorporate components produced by multiple iterations of the method of Figure 3. Being able to identify components during assembly, use, maintenance, or repair of such systems has many advantages, as described below. Such mass-produced systems include the load handling device described above. The load handling device referenced above may be a mobile grocery picking robot.

[0041] FIG. 5 illustrates a system 500 used to implement the method of FIG. 3. A computing device 510 is used to control a PBFAM system 520. The computing device 510 receives or generates a file 515 comprising several components to be produced as a batch using the PBFAM system. The file 515 can be a nesting file that controls where each component in the batch is located within the build volume (as determined by a nesting algorithm). The components in the file can be generated from computer-aided design (CAD) software. As shown in FIG. 4, each component is assigned an area 420 on the component designated for an identifier. The designated area can be an area that makes the unique identifier easily accessible to a reading device such as a camera or scanner. Similarly, the designated area can be located in an area that does not adversely affect the performance of the component, such as a large or strong area. The computing device assigns the unique identifier and updates the file so that each component is produced with its respective unique identifier in the designated area. The PBFAM system is then used to produce the batch of components, each with its respective unique identifier in the area designated for it. The computing device maps each unique identifier to at least one property of the respective component. Each unique identifier, the at least one property, and the associated mapping may then be stored in database 530.

[0042] Although shown as separate elements, it will be understood that a single piece of hardware can implement the functionality of the computing device, the PBFAM system, and the database. For example, the PBFAM system can be programmed to process the file before printing and store each assigned unique identifier, at least one property, and associated mapping locally or on a network device. Alternatively, the PBFAM system can interface with a cloud computing platform to receive the file and store each unique identifier, at least one property, and associated mapping. As shown in FIG. 5, there is bidirectional communication between each of the computing device, the PBFAM system, and the database. This means that each of the computing device, the PBFAM system, and the database can send and receive data from each other to implement the method of FIG. 3.

[0043] The at least one property may include at least one manufacturing property including at least one of the following: a respective location of each component of a batch of components within the build volume of the PBFAM system; a powder bed temperature setting of the PBFAM system; an energy source setting of the PBFAM system (the energy source may be understood as converting the current powder layer into an individual layer or cross-section of the component); a rate of powder spreading of the PBFAM system; an inkjet array setting of the PBFAM system; at least one material used in the PBFAM system; a model of the PBFAM system; a job number of the PBFAM system; a batch number of the batch of components; a material from which the component is manufactured by the PBFAM system; and a time and / or duration of manufacturing the batch of components. Generally, the manufacturing property of a component should provide a comprehensive understanding of how exactly and under what conditions the component was manufactured. It will be understood that the manufacturing property may be generated by analyzing manufacturing data from the PBFAM system itself at any time before, during, and after manufacturing of the component. Additionally, the manufacturing property may be updated in real time during the manufacturing process. Similarly, this information may be generated by the computing device 510 when preparing the file 515.

[0044] One option for generating the respective positions of each component of a batch of components within the build volume of the PBFAM system is to analyze a nesting file used to control where each component is located within the build volume. The nesting file may be part of file 515. The nesting file defines each position in terms of, for example, X, Y, and Z coordinates, which can provide both absolute and relative position and orientation of each component. In one example, each position should identify the relative position of a given component, but it can also indicate which other components have been formed in the immediately surrounding area. Furthermore, a nesting file can be saved for each component, with associated components identified. This means that the exact context in which each component was manufactured is saved in the database.

[0045] The at least one property may include information including at least one of the component's serial number (which may be the same as the unique identifier in some implementations), the component's design, a description of the component and its function, installation instructions for the component, the system in which the component is used, the component's revision number, the component's compatibility with other components or the system in which the component is used, the location within the load handling device in which the component is used, the component's geometric dimension and tolerance data, and the component's development history. The information may also include feedback about the component, including performance metrics such as failures, malfunctions, usage cycles before failure, wear and tear, etc. (It will be understood that this type of information can be observed or generated from analyzing the component's CAD file or software that simulates the component's performance.) In general, the information about the component should provide a comprehensive understanding of all aspects of the component design, the component itself, and the component's use. Of course, this information can also be updated during the product's life using measurement / observation data, as described below, for example, with reference to FIGS. 8 and 9.

[0046] After the manufacturing process is complete, the component's unique identifier can be used to retrieve a mapping in a database to at least one property of the component. The unique identifier can be read using appropriate hardware, such as a camera with OCR, QR code, or barcode recognition capabilities. Alternatively, an operator can visually inspect and record the charter string-based identifier. Thus, for any component with a unique identifier, it is possible to gain a comprehensive understanding of all aspects of the component, including how exactly it was manufactured. This comprehensive understanding can be applied to optimize both the component and its use.

[0047] FIG. 6 illustrates a method 600 for optimizing a component. In step 610, the performance of at least one component of a batch of components is determined. Performance can be determined by evaluating the component against certain metrics related to component quality, such as strength, elasticity, plasticity, hardness, toughness, brittleness, stiffness, ductility, malleability, cohesion, impact strength, fatigue, creep failure rate, failure location / area on the component, and use cycles before failure. Generally, a performance metric is one that allows for an evaluation of the quality of a component. It is desirable to maximize component quality, which may involve consideration of several performance metrics. Of course, the number of metrics used to determine quality, and what is considered acceptable quality, will vary depending on the nature and use of a given component. It will be understood that performance metrics can be measured and / or simulated.

[0048] In step 620, if it is determined that the performance of a given component can be improved, i.e., that the component has unacceptable quality, the component's unique identifier is used to determine at least one property of the component. Typically, there is a causal relationship between at least one property and the component's performance. In other words, a performance metric depends on at least one property. For example, material stiffness depends on the component's structure and the material from which the component is made. Another example is when a failure area can be attributed to a lack of structural reinforcement in the underlying design. This can occur when a component is attached to another component during use, for example, by a bolt, and torque applied to the bolt can damage the component. Another example is when a component splits along one of its axes, which can be traced back to the orientation the component had in the build volume. Yet another example is when the location / orientation of a component during formation can affect its cooling rate. Also, a component may be used in an incompatible system. In general, a desired improvement in component performance can be achieved by considering the causal relationship between the performance metric and the component's properties. Thus, the process of FIG. 6 can be fully automated using knowledge of these causal links. Simulations can be used to verify whether the proposed modified properties result in the desired improvement.

[0049] Thus, in step 630, the properties of the component are modified to provide improvements when the next version of the component is subsequently generated. For example, the material or even the process by which the component is made can be changed to improve stiffness. Another example is the addition of reinforcement regions to improve torque resilience. Yet another example is giving the component a different orientation within the build volume so that the axis of failure does not align with an axis within the build volume, resulting in structural weakness compared to other axes within the build volume.

[0050] In step 640, a component having the modified properties is then manufactured. Thus, the subsequently modified component has improved performance, such as the examples listed above, i.e., improved stiffness, or torque resistance, or increased strength along a given axis. However, as noted above, the component may have been determined to have unacceptable quality due to its use in an incompatible system. The modified properties may be updated compatibility information. This helps ensure that future versions of the component are used only with compatible components and / or systems, so that previous quality issues do not reappear. For example, a component may be designed to withstand certain forces that are exceeded in certain systems. Restricting subsequent versions of this component from use in those specific systems means that it will not be subjected to forces that adversely affect its performance.

[0051] It will be appreciated that step 630 may be used to produce a single component by any suitable manufacturing technique, but the component may form part of a subsequent batch of components produced using the PBFAM system or the method of FIG. 3 and the system of FIG. 5. In this manner, each component in the subsequent batch of components has a respective identifier indicating at least one property, one of which is altered compared to comparable properties in the batch of components. Component performance in the batch of components may also be added to the database. This allows iterative changes in component quality to be linked to modified parameters, ultimately helping to optimize the component.

[0052] One advantage of using a PBFAM system is that the nesting file for a subsequent batch of components can be modified to implement at least one property modification. Furthermore, the nesting file can be used to implement modifications to several components within the subsequent batch of components. For example, the available rotational degrees of freedom for each component can be constrained, components can be prioritized, no-build zones can be defined to ensure minimum spacing between parts, sacrificial cases / covers can be used to group and / or protect certain components, the total number of components within the build volume can be changed, and the thickness of each PBFAM layer (as determined by slicing the 3D CAD file) can be modified within the PBFAM system. Similarly, PBFAM settings can be modified, such as the PBFAM system's powder bed temperature setting, the PBFAM system's energy source setting, the PBFAM system's powder application rate, and the PBFAM system's inkjet array setting. At a general level, the PBFAM system can be configured to improve the quality of components within subsequent batches.

[0053] It will be appreciated that the method of Figure 6 is not necessarily limited to improving only components manufactured using the method of Figure 3 and the system of Figure 5. For example, a legacy component manufactured by a different means or a different manufacturing method may still have an identifier, such as a post-manufacture label, and a corresponding entry in a database. Thus, the method of Figure 6 can be used to analyze the component, thereby optimizing the design of the legacy component when the next version of the component is subsequently manufactured.

[0054] FIG. 7 illustrates a method 700 for identifying all components that may have adverse performance due to a common property. As in steps 610 and 620 of FIG. 6 , once it is determined that a component's performance can be improved, it is determined 710 whether at least one component of the plurality of components has a property similar to or identical to the component whose performance has been determined to be improved. Upon determining that at least one component of the plurality of components has a property similar to or identical to the component whose performance has been determined to be improved, at least one respective unique identifier for at least one of the plurality of components is provided 720. This means that all components with entries in the database can be examined, and potential adverse performance issues can be preemptively addressed. For example, future versions of these components may have at least one property modified to improve performance as described above. Alternatively, existing components may have their future use restricted and / or recalled.

[0055] FIG. 8 illustrates a method 800 by which a user can provide and edit information for a component produced using the above-described method and system. In a first step, the method interfaces with a database, such as database 530, so that a user can search for a unique identifier 810. Identifying the unique identifier provides information about at least one property associated with the component in which the unique identifier is located 820. At this point, all of the properties listed above can be displayed. An image of the component can also be displayed. Hyperlinks to related components, installation guides, and systems in which the component is used can also be provided. At the same time, extensive history and knowledge of all aspects of the component is provided. The user can review these properties and edit any of them 830. It will be appreciated that the properties may not yet be complete, in that some properties do not yet have values, i.e., are blank entries. Thus, when editing, the user can both modify existing properties and / or provide new properties. For example, the user may update the component's compatibility or provide feedback regarding the component's installation, such as the appropriate torque wrench setting. The edited at least one property is then stored 840.

[0056] If the unique identifier search 810 is not found in the database, the user may be prompted to create an entry for the component with which it is associated. This may occur with legacy components or with incorrectly merging databases. Even if a user can provide limited information, such as properties indicating the system in which the component is currently used or a photo of the component, other users may add additional properties to allow them to assimilate a better understanding of the component. It will be appreciated that the method of FIG. 8 provides access to information regarding the properties listed above, including information and manufacturing properties for a given component.

[0057] Additionally, the methods of Figures 6 and 7 can use the method of Figure 8. With respect to Figure 6, components may be identified by searching for unique identifiers so that associated properties stored in a database can be analyzed, which in turn allows improved performance to be predicted / simulated. With respect to Figure 7, components with similar or identical properties can be grouped so that a search for any component in that group returns a list of all components in the group.

[0058] FIG. 9 illustrates a user interface / front end 900 that may be used as part of the method of FIG. 8. As shown, a search for a unique identifier returns a database entry 910 for the component in which the unique identifier was found. Properties 920, such as those listed above, are displayed. It will be understood that the properties listed above are actually metadata for the component. The user interface / front end 900 provides access to this metadata. Hyperlinks 930 are provided to retrieve further information and / or properties of the component. The hyperlinks may link, for example, to related components, installation guides, and systems in which the component is used. In one example, the link may be to a kit of components of which the component is a part. The kit of components may be for the load handling device or mobile grocery picking robot referenced above. The kit of components may be part of an installation / build guide for the load handling device or mobile grocery picking robot.

[0059] In all of the above-described methods and systems, the respective identifiers may also be used to indicate features of the component. For example, if the component has at least one opening for receiving a nut or bolt, a particular character in the respective identifier may indicate the size of the nut or bolt to be used (e.g., M12). Additionally or alternatively, the torque wrench setting for installing the bolt may be indicated. Additionally or alternatively, the feature markers may be used in any suitable location on the component. For example, if the component has several openings for receiving nuts or bolts, appropriate feature markers may be used near each opening. Generally, the feature markers indicate areas on the component where a particular use and / or installation of the component occurs.

[0060] Although the methods and systems described above are used in the context of using a PBFAM system, it will be appreciated that any AM system that uses batch manufacturing, or even a non-AM system, may be used.

[0061] As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0062] The present invention can take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment containing both hardware and software elements. In a preferred embodiment, the present invention is implemented in software.

[0063] Furthermore, the present invention may take the form of a computer program product embodied as a computer-readable medium having computer-executable code thereon for use by or in connection with a computer. In the context of this document, a computer-readable medium may be any tangible apparatus that can contain, store, communicate, propagate, or transfer a program for use by or in connection with a computer. Furthermore, a computer-readable medium may be an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system (or apparatus or device) or a propagation medium. Examples of computer-readable media include semiconductor or solid-state memory, magnetic tape, removable computer diskettes, random access memory (RAM), read-only memory (ROM), rigid magnetic disks, and optical disks. Current examples of optical disks include compact disks - read-only memory (CD-ROM), compact disks - read / write (CD-R / W), and DVDs.

[0064] The flow diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of methods according to various embodiments of the present invention. In this regard, each block in the flow diagrams may represent a module, segment, or portion of code, comprising one or more executable instructions for implementing specified logical functions. It should also be noted that in some alternative implementations, the functions shown in the blocks may occur out of the order shown in the figures. For example, depending on the functionality involved, two blocks shown in succession may in fact be executed substantially concurrently, or the blocks may be executed in the reverse order. It should also be noted that each block of the flow diagrams, and combinations of blocks in the flow diagrams, may be implemented by a special-purpose hardware-based system that performs the specified functions or operations, or executes a combination of special-purpose hardware and computer instructions.

[0065] It will be understood that the above description is given by way of example only, and that various modifications may be made by those skilled in the art. Although various embodiments have been described above with a certain degree of particularity or with reference to one or more individual embodiments, those skilled in the art could make numerous changes to the disclosed embodiments without departing from the scope of the invention.

[0066] The following is a non-exhaustive list of embodiments that can be or will be claimed.

[0067] 1. A method for manufacturing a component, comprising: assigning a respective unique identifier to each respective component of the batch of components; and manufacturing a batch of components using a manufacturing system, wherein each component of the batch of components includes a respective unique identifier.

[0068] 2. The method of embodiment 1, wherein the manufacturing system comprises an additive manufacturing (AM) system.

[0069] 3. The method of embodiment 2, wherein the AM system comprises a Powder Bed Fused Additive Manufacturing (PBFAM) system.

[0070] 4. The method of embodiment 3, wherein the method further comprises interfacing with and updating a nesting file to manufacture each component of the batch of components with a respective unique identifier.

[0071] 5. The method of any one of embodiments 3 or 4, wherein each respective unique identifier indicates at least one property of a respective component of the batch of components.

[0072] 6. The method of embodiment 5, wherein the at least one property comprises a manufacturing property.

[0073] 7. At least one manufacturing property is the respective locations of each component of the batch of components within the build volume of the PBFAM system; Powder bed temperature setting for PBFAM system, Energy source setting for PBFAM system, Powder application rate of the PBFAM system, Inkjet array setup for the PBFAM system, At least one material used in the PBFAM system; Model of the PBFAM system, PBFAM system job number, the material from which the component is made, Batch number of the batch of components, the time and / or duration of the manufacture of a batch of components; 7. The method of embodiment 6, comprising at least one of:

[0074] 8. The method of embodiment 6 or 7, further comprising interfacing with a nesting file to receive respective positions within the build volume or at least one manufacturing property.

[0075] 9. How to Powder bed temperature setting for PBFAM system, Energy source setting for PBFAM system, The rate of powder application of the PBFAM system, and PBFAM inkjet array settings, 9. The method of embodiment 7 or 8, further comprising interfacing with a PDFAM system to receive at least one of:

[0076] 10. The method of embodiment 9, wherein at least one of the powder bed temperature setting of the PBFAM system, the energy source setting of the PBFAM system, the powder diffusion rate of the PBFAM system, and the inkjet array setting of the PBFAM system is received in real time as the component is manufactured.

[0077] 11. At least one property comprises information, and the information comprises: component design, Component description, Component installation instructions, the system in which the component is used; Component revision number, the compatibility of the component with other components or systems in which the component is used; component geometric dimension and tolerance data, the location within the load handling device where the component is used; 11. The method of embodiment 5 to 10, comprising at least one of:

[0078] 12. How to mapping at least one property to a respective unique identifier for each component; 12. The method of claim 5, further comprising: using the mapping to indicate at least one property of each component.

[0079] 13. The method of embodiment 12, further comprising storing the respective unique identifier, at least one property, and mapping for each component in a database.

[0080] 14. How to Determining the performance of at least one component of the batch of components; Upon determining that performance of the at least one component can be improved, using the unique identifier of the at least one component to determine at least one property of the component; Modifying at least one property of the component to improve performance; 14. The method of any preceding embodiment, further comprising: manufacturing a component having at least one modified property.

[0081] 15. A method comprising: Determining the performance of at least one component of the batch of components; Upon determining that performance of the at least one component can be improved, using the unique identifier of the at least one component to determine at least one property of the component; Modifying at least one property of the component to improve performance; and manufacturing a component having at least one modified property.

[0082] 16. The method of embodiment 14 or 15, wherein manufacturing a component having at least one modified property comprises manufacturing the component as part of a subsequent batch of components using a PBFAM system.

[0083] 17. At least one property of the components of the batch of components comprises a mechanical property, including their respective locations within the build volume of the PBFAM system in which the batch of components was manufactured; 17. The method of embodiment 16, wherein modifying at least one property of the components of the subsequent batch of components comprises modifying their respective positions within a build volume of a PBFAM system that manufactures the subsequent batch of components.

[0084] 18. The method is 18. The method of embodiment 17, further comprising interfacing with the nesting file to modify the respective positions within the build volume of the PBFAM system that manufactures the subsequent batch of components.

[0085] 19. Correcting each position is Constraining the rotational degrees of freedom of each component; Prioritizing components; and defining a no-build zone to ensure minimum spacing between parts; forming a sacrificial case / cover to group and / or protect certain components; Varying the total number of components in the build volume; 19. The method of embodiment 17 or 18, comprising at least one of: varying the thickness of each PBFAM layer used to form a component in the PBFAM system.

[0086] 20. At least one property of a component in a batch of components is a mechanical property comprising at least one of the powder bed temperature setting of a PBFAM system, an energy source setting of a PBFAM system, a powder diffusion rate of a PBFAM system, and an inkjet array setting of a PBFAM system; 16. The method of claim 14 or 15, wherein altering at least one property of the components of the subsequent batch of components comprises altering at least one of the powder bed temperature setting of the PBFAM system producing the subsequent batch of components, the energy source setting of the PBFAM system producing the subsequent batch of components, the powder diffusion rate within the PBFAM system producing the subsequent batch of components, and the inkjet array setting of the PBFAM system producing the subsequent batch of components.

[0087] 21. The method of any one of embodiments 14 to 20, wherein the method further comprises assigning a respective unique identifier to the component or each respective component of a batch of subsequent components.

[0088] 22. Each respective identifier indicates at least one property of a respective component of a subsequent batch of components; 22. The method of embodiment 21, wherein each component of the subsequent batch of components is provided with a respective unique identifier.

[0089] 23. The method is determining whether at least one component of the plurality of components has similar or identical properties to the component whose performance has been determined to be improved; 23. The method of any one of embodiments 14 to 22, further comprising, upon determining that at least one component of the plurality of components has similar or identical properties to a component whose performance has been determined to be improved, providing a unique identifier for the or each component of the plurality of components.

[0090] 24. The method of any preceding embodiment, wherein the unique identifier indicates a characteristic of the component, or wherein manufacturing a batch of components further comprises forming at least one characteristic identifier on the component.

[0091] 25. The method of any one of embodiments 1 to 24, wherein each respective identifier is formed by embossing or debossing on each respective component, or the method of embodiment 24, wherein at least one feature identifier is formed by embossing or debossing on each respective component.

[0092] 26. A method according to any preceding embodiment, wherein each component of a batch of components is provided with a respective unique identifier on a designated area of ​​the component.

[0093] 27. A computer program comprising instructions, which when executed by a computer, causes the computer to perform a method according to any one of embodiments 1 to 26.

[0094] 28. A data processing system comprising a processor configured to perform the method of any one of embodiments 1 to 26.

[0095] 29. A mobile grocery picking robot or load handling device having a component manufactured by the method of any one of embodiments 1 to 26.

[0096] 30. A component manufactured by the method of any one of embodiments 1 to 26.

[0097] 31. A computer-implemented method for determining a property of a component, comprising: searching a database for a unique identifier; Locating the unique identifier provides at least one property associated with the component; receiving at least one input for editing the at least one property associated with the component; and storing the edited at least one property.

[0098] 32. The method of embodiment 31, wherein the at least one property comprises a manufacturing property.

[0099] 33. At least one manufacturing property is the respective locations of each component of the batch of components within the build volume of the PBFAM system; Powder bed temperature setting for PBFAM system, Energy source setting for PBFAM system, Powder application rate of the PBFAM system, Inkjet array setup for the PBFAM system, At least one material used in the PBFAM system; Model of the PBFAM system, PBFAM system job number, Batch number of the batch of components, the material from which the component is made, the time and / or duration of the manufacture of a batch of components; 33. The method of embodiment 32, comprising at least one of:

[0100] 34. At least one property comprises information, and the information is component design, Component description, Component installation instructions, the system in which the component is used; Component revision number, the compatibility of the component with other components or systems in which the component is used; component geometric dimension and tolerance data, the location within the load handling device where the component is used; 34. The method of embodiment 31 to 33, comprising at least one of:

[0101] 35. The method of any one of embodiments 31 to 34, wherein an image of the component is displayed when the unique identifier is located.

[0102] 36. The method of any one of embodiments 31 to 35, wherein receiving at least one input comprises receiving at least one input from a user or a computing device.

[0103] 37. A computer program comprising instructions, which when executed by a computer, causes the computer to perform the method of any one of embodiments 31 to 36.

[0104] 38. A data processing system comprising a processor configured to perform the method of embodiments 31 to 36.

[0105] 39. A computer-implemented method for generating nesting files for manufacturing components using a Powder Bed Fused Additive Manufacturing (PBFAM) system, comprising: receiving a nesting file; assigning a respective unique identifier to each respective component of the batch of components; updating the nesting file so that each component of a batch of components includes a respective unique identifier when manufactured using the PBFAM system.

[0106] 40. The method is mapping at least one property to a respective unique identifier for each component; 40. The method of embodiment 39, comprising using an updated nesting file to indicate at least one property of each component.

[0107] 41. The method of embodiment 40, wherein the at least one property comprises a manufacturing property.

[0108] 42. At least one manufacturing property is the respective locations of each component of the batch of components within the build volume of the PBFAM system; Powder bed temperature setting for PBFAM system, Energy source setting for PBFAM system, Powder application rate of the PBFAM system, Inkjet array setup for the PBFAM system, At least one material used in the PBFAM system; Model of the PBFAM system, PBFAM system job number, Batch number of the batch of components, the material from which the component is made, 42. The method of embodiment 41, comprising at least one of: time and / or duration of production of a batch of components.

[0109] 43. At least one property comprises information, and the information is component design, Component description, Component installation instructions, the system in which the component is used; Component revision number, the compatibility of the component with other components or systems in which it is used; component geometric dimension and tolerance data, 42. The method of embodiment 40 or 41, comprising at least one of: a location within a load handling device where the component is used.

Claims

1. 1. A method for component manufacturing, comprising: assigning a respective unique identifier to each respective component of the batch of components; and manufacturing the batch of components using a Powder Bed Fused Additive Manufacturing (PBFAM) system, wherein each component of the batch of components comprises a respective unique identifier.

2. The method of claim 1 , further comprising interfacing with and updating a nesting file to manufacture each component of the batch of components with the respective unique identifier.

3. The method of claim 1 or 2, wherein each respective unique identifier indicates at least one property of a respective component of the batch of components.

4. The method of claim 3 , wherein the at least one property comprises a manufacturing property.

5. At least one manufacturing property is a respective location of each of the components of the batch of components within a build volume of the PBFAM system; the powder bed temperature setting of said PBFAM system; Setting the energy source of the PBFAM system; the powder application rate of the PBFAM system; Inkjet array settings of the PBFAM system; At least one material used in said PBFAM system; a model of the PBFAM system; the job number of the PBFAM system; the batch number of the batch of said component; the material from which said component is made; the time and / or duration of the production of a batch of said components; The method of claim 4 , comprising one of:

6. The method of claim 5 , wherein the method further comprises interfacing with a nesting file to receive the respective positions within the build volume.

7. The method comprises: the powder bed temperature setting of the PBFAM system; the energy source setting of the PBFAM system; the rate of powder application of the PBFAM system; and Inkjet array settings of the PBFAM system; The method of claim 5 or 6, further comprising interfacing with the PDFAM system to receive at least one of:

8. 8. The method of claim 7, wherein at least one of the powder bed temperature setting of the PBFAM system, the energy source setting of the PBFAM system, the powder diffusion rate of the PBFAM system, and the inkjet array setting of the PBFAM system is received in real time as the component is manufactured.

9. The at least one property comprises information, the information comprising: the design of said component; a description of said components; installation instructions for said components; a system in which said component is used; the revision number of said component; the compatibility of the component with other components or systems in which the component is used; geometric dimension and tolerance data of said component; the location within the load handling device where said component is used; The method of claim 3 , further comprising at least one of:

10. The method comprises: mapping said at least one property to a respective unique identifier for each component; The method of claim 3 , further comprising: using the mapping to indicate the at least one property of each component.

11. The method of claim 10 , further comprising storing the respective unique identifier of each component, the at least one property, and the mapping in a database.

12. The method comprises: determining the performance of at least one component of the batch of components; upon determining that the performance of at least one component can be improved, using the unique identifier of the at least one component to determine at least one property of the component; Modifying at least one property of the component to improve performance; The method of claim 1 , further comprising: manufacturing the component having the modified at least one property.

13. The method of claim 12 , wherein manufacturing the component having the at least one modified property comprises manufacturing the component as part of a subsequent batch of components using a PBFAM system.

14. At least one property of the components of the batch of components comprises a mechanical property with a respective location within a build volume of the PBFAM system that produced the batch of components; 14. The method of claim 13, wherein modifying at least one property of the components of the subsequent batch of components comprises modifying the respective positions within a build volume of the PBFAM system that manufactures the subsequent batch of components.

15. The method comprises: The method of claim 14 , further comprising interfacing with a nesting file to modify the respective positions within the build volume of the PBFAM system that manufactures the subsequent batch of components.

16. Modifying the respective positions includes: Constraining the rotational degrees of freedom of each component; Prioritizing components; and Defining no-build zones to ensure minimum spacing between parts; forming a sacrificial case / cover to group and / or protect certain components; Varying the total number of components in the build volume; Varying the thickness of each PBFAM layer used to form the component in the PBFAM system; 16. The method of claim 14 or 15, comprising at least one of:

17. At least one property of the components of the batch of components is mechanical properties comprising at least one of the powder bed temperature setting of the PBFAM system, the energy source setting of the PBFAM system, the powder diffusion rate of the PBFAM system, and the inkjet array setting of the PBFAM system; 13. The method of claim 12, wherein altering at least one property of the components of a subsequent batch of components comprises altering at least one of a powder bed temperature setting of the PBFAM system producing the subsequent batch of components, the energy source setting of the PBFAM system producing the subsequent batch of components, a powder diffusion rate within the PBFAM system producing the subsequent batch of components, and the inkjet array setting of the PBFAM system producing the subsequent batch of components.

18. 18. The method of any one of claims 12 to 17, wherein the method further comprises assigning each respective component of the component or subsequent batch of components a respective unique identifier.

19. each respective identifier indicating at least one property of a respective component of said subsequent batch of components; 20. The method of claim 18, wherein each component in the subsequent batch of components comprises a respective unique identifier.

20. The method comprises: determining whether at least one component of the plurality of components has properties similar or identical to the component whose performance has been determined to be improved; 20. The method of claim 12, further comprising, upon determining that at least one component of the plurality of components has similar or identical properties to the component whose performance has been determined to be improved, providing the or each respective unique identifier for the or each component of the plurality of components.

21. 21. The method of claim 1, wherein the unique identifier indicates a characteristic of the component, or wherein manufacturing a batch of the component further comprises forming at least one characteristic identifier on the component.

22. 22. The method of any one of claims 1 to 21, wherein each respective identifier is formed by embossing or debossing on each respective component; or the method of claim 21, wherein the at least one feature identifier is formed by embossing or debossing on each respective component.

23. 23. A method according to any preceding claim, wherein each component of the batch of components is provided with the respective unique identifier on a designated area of ​​the component.

24. A computer program comprising instructions which, when executed by a computer, cause the computer to carry out the method of any one of claims 1 to 23.

25. 24. A data processing system comprising a processor configured to perform the method of any one of claims 1 to 23.

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