Integrated system 3D printing services equipped with artificial intelligence

Abstract

The invention of integrated system of polymer and metal 3d printing services of volumes equipped with artificial intelligence is a type of network for receiving print orders based on artificial intelligence which the artificial intelligence server with the ability to learn and make decisions about choosing a printer, modifying software files and optimizing the printing process. Also this invention is related to a 3D printer and a network of 3D printers and related to a 3D printer with at least one camera for monitoring the printing process and related to techniques for monitoring a three-dimensional (3D) printer during a print job and related to cleaning needles for unblocking the nozzles of the printer head. Among the advantages of the mentioned system is equipping the printer with a smart multi-size cleaning system.

Description

[0001] INTEGRATED SYSTEM 3D PRINTING SERVICES EQUIPPED WITH ARTIFICIAL INTELLIGENCE

[0002] TECHNICAL FIELD OF THE INVENTION

[0003] The present invention is related to a 3D printer and a network of 3D printers and related to a 3D printer with at least one camera for monitoring the printing process and related to techniques for monitoring a three-dimensional (3D) printer during a print job and related to cleaning needles for unblocking the nozzles of the printer head.

[0004] PRIOR ARTS

[0005] Now, 3D printers are divided into two categories based on the used material, polymer and metal printers. In polymer printers, the process of producing parts (printing) using a polymer strip with a circular or flat cross-section is used. With the advancement of the said ribbon in the printer head and through the heat in the head, the polymer tape is melted, and then with the increase of the feed of the print tape, the pressure in the nozzle of the head has increased and the piece is formed by laminating different layers of molten material from the printer head, and as the height of the piece increases, the distance between the head and the device support also increases. In metal models, using metal powder with a low melting temperature and then creating a high-power laser beam, the molecular melting of the metal powder will occur, and as a result, the new melting material will stick together with the previous melting material and form the parts. 3D printing is used in various industries, including manufacturing, prototyping, healthcare, aerospace, automotive, and consumer goods. It enables rapid prototyping, customization, and the production of complex geometries that may be challenging or impossible with traditional manufacturing methods.

[0006] A 3D printer is a type of additive manufacturing technology that creates three- dimensional objects layer by layer from a digital model. Instead of traditional subtractive manufacturing processes, where material is removed to shape an object, 3D printing builds up the object layer by layer. This process is also known as additive manufacturing because it adds material gradually to create the final product. The first step is to create a digital 3D model of the object you want to print. The 3D model is then sliced into thin layers using slicing software. Each layer represents a cross-section of the final object. The sliced layers are sent to the 3D printer, which then builds the object layer by layer. Various 3D printing technologies exist, including Fused Deposition Modeling (FDM), Stereolithography (SEA), Selective Easer Sintering (SLS), and others. These technologies use different materials and techniques to create the final object.

[0007] The 3D printer nozzle is a critical component responsible for depositing material layer by layer to create a three-dimensional object. The nozzle is part of the extruder, which is the component that feeds and melts the filament, guiding it to the print bed in a controlled manner. As the nozzle moves along the X, Y, and Z axes based on the 3D model's instructions, it extrudes the molten filament in thin layers onto the print bed or the previous layers. The material cools and solidifies rapidly, forming the desired shape. Cleaning the 3D printer nozzle is essential to maintain proper functionality and ensure high-quality prints. Nozzles can become clogged with leftover filament, debris, or other contaminants, affecting the extrusion process. Webcams can be set up to the printers to monitor the 3D printing process remotely. Also, there are mobile apps designed for specific 3D printers or that work with OctoPrint, allowing to monitor and control the 3D printer from smartphone or tablet.

[0008] In this regard, it can mention to the below inventions which are related to the cleaning methods of the 3D printer nozzles as well as remote monitoring of the printing process:

[0009] A Chinese invention with patent number CN210082426U which is granted dated 18 / 02 / 2020 titled “Clean integration hot bed of 3D print head” discloses a clean integration hot bed of 3D print head, including hot bed, the edge of hot bed is provided with an extension, the fixed surface is provided with hollow negative pressure production device under the extension, the negative pressure produces the sealed step motor that is provided with of device, the negative pressure produce the device upper end sealed rotate with sealed be provided with vertical up and with the clean needle of cavity that the step motor drive is connected, the negative pressure produces the device lower extreme and is provided with negative pressure generater interface, the negative pressure generater interface is connected with the getter device through the straw. The utility model discloses can clean the inside remaining printing material of shower nozzle effectively, prevent that it from bruising stifled to influence next time printing, simple structure, convenient and fast in the nozzle.

[0010] In a Chinese invention with patent number CN110053254A which is granted dated 27 / 10 / 2023 titled “3D printer and 3D printing method” discloses a kind of 3D printer and 3D printing methods are related to the technical field of 3D printing. The 3D printer of the application, including cabinet, environmental control module, Switch of working position module, spray head mobile module, material conveyor module, temperature control module and main control module, conveying spray head, multiple stations and multiple printing vessel are equipped in cabinet, convey the top that spray head is set to station, it prints vessel to be arranged on station, conveying spray head includes printing head. Environmental control module is set in cabinet. Switch of working position module is set in cabinet, for driving printing vessel to be shifted between each station. Spray head mobile module is connected with printing head, for driving printing head to be shifted between each station. Material conveyor module is connected with conveying spray head, for conveying material to conveying spray head. Temperature control module is set on material conveyor module, station and printing head, for adjusting temperature.

[0011] Another Chinese invention with patent number CN110126276A which is granted dated 05 / 02 / 2021 titled “a kind of can in 3D printer nozzle automatic telescopic cleaning plant” relates to Intelligent office cleaning technology fields, and disclose it is a kind of can in 3D printer nozzle automatic telescopic cleaning plant, including nozzle, heating head and trunnion, enclosure interior middle position is provided with coolant liquid storage tube, coolant liquid storage tube front end is fixedly connected with turntable, the turntable top is fixedly connected with sealing ring, the shell end is provided with push rod and extends to enclosure interior, the push rod front position is equipped with motor, the sealing ring top is fixedly connected with cleaning tube and extends to sealing ring end, the cleaning tube surface is provided with barb apparatus. Pass through setting cleaning tube and push rod and barb apparatus, achieve the effect that keep cleaning plant more convenient to use without dismantling directly cleaning impurity, pass through setting hangnail, spring and electric machine structure, reach the free extension in spray head to clear up, the better purpose of cleaning effect.

[0012] A Chinese invention with patent number CN111136913A which is granted dated 09 / 10 / 2020 titled “Quick dredging equipment for blockage of 3D printer nozzle” discloses a 3D printer nozzle blockage rapid dredging device which comprises a cleaning pen, wherein a working cavity with a right opening is formed in the right end face of the cleaning pen, a rotating cavity with a downward opening is formed in the upper end wall of the working cavity, a detection mechanism is arranged in the working cavity and comprises a torsion spring groove arranged on the rear end wall of the rotating cavity, a moving mechanism is arranged in the working cavity and comprises a protection rod fixed on the left end wall of the working cavity, a reset groove is formed in the protection rod, a telescopic rod is arranged in the reset groove in a left-and-right moving mode, a motor cavity is formed in the cleaning pen, the motor cavity is arranged on the left side of the working cavity, a rotating mechanism is arranged in the motor cavity and comprises a motor fixed on the upper end wall of the motor cavity, the device can dredge a nozzle and heat and melt residual materials in the nozzle, the negative pressure is used for sucking out the waste water.

[0013] In a Chinese invention with patent number CN207273897U which is granted dated 27 / 04 / 2018 titled “A kind of 3D printing spray head cleaning device” provided a kind of 3D printing spray head cleaning device, Including shell, Shell rear and front end inner surface is connected with limiting device by threads turn, Inner surface is rotatably connected to hard cleaning device at the lower end center of the shell, Inner surface is fixedly connected with soft cleaning sprayer at the upper end center of the shell, The soft cleaning sprayer lower end inside surface is equipped with spray orifice, The soft cleaning sprayer rear inside surface is rotatably connected to conduit by internal thread, The front and back end outer surface of the conduit is fixedly connected with quoit, The quoit front end outer side surface slidably connects rubber pad, The rear end of conduit outer surface is rotatably connected to water pump, The 3D printing spray head cleaning device realizes two kinds of different cleaning methods, Hard cleaning and soft cleaning, With variability, Using flexible, It is thorough that cleaning is used in combination in two methods during use. Also in a Japanese invention with patent number JP5678018B2 which is granted dated 25 / 02 / 2015 titled “Apparatus and method for maintenance and inspection of 3D printer” relates to apparatus and methods for producing three- dimensional objects through building of successive layers printed by e.g. inkjet print heads. For aligning the print heads a test pattern is used, made up of alternating reference lines and test lines, both parallel and perpendicular to a fast-axis travel, the test lines comprising test bars incrementally displaces around a central test bar. Cleaning of the print heads is also provided. The test pattern is read by alignment sensor system and analyzed with a Fast Fourier Transform (FFT).

[0014] And in an US invention with publication number US20220055300A1 which is filed dated 01 / 11 / 2021 titled “Systems and methods for 3D printing with multiple exchangeable print heads” is a modular 3D printer system can include a base subsystem and multiple exchangeable components. The base subsystem can have a 3D motion module, a print head module and a platform module. The multiple exchangeable components can include print heads having different configurations and functionalities, which can be exchangeably installed in the print head module. The multiple exchangeable components can include platform supports having different configurations and functionalities, which can be exchangeably installed in the platform module.

[0015] In a Japanese invention with patent number JP5992943B2 which is granted dated 14 / 09 / 2016 titled “Printed matter inspection apparatus, printed matter transfer control device using the same, and printed matter inspection method” relates to a printed matter inspection apparatus, a printed matter conveyance control device using the printed matter, and a printed matter inspection method, and more particularly to a printed matter inspection device that detects a printing defect from the frequency of occurrence of defective printed matter, and a printed matter conveyance control device and printed matter inspection using the printed matter inspection device. The determination unit inputs a determination signal that has been determined to be correct from the image of the printed material that has been continuously printed by the camera, and the occurrence information of the defective printed material (such as broken paper) included in the signal is captured image of the printed material and judgment is made for each sheet.

[0016] A Taiwanese invention with patent number TWI572497B which is granted dated 01 / 03 / 2017 titled “A system and method for network-monitoring of 3d printing” relates to 3D printing technology, and more particularly to a 3D printing network monitoring system and method. A 3D printing network monitoring system for monitoring a 3D printing machine to print a line of printing, the 3D printing network monitoring system comprises: a network information module, connected to the 3D printing machine, a network address for setting and storing the 3D printer, a network address of a remote transceiver device, and an interval for periodically transmitting a network message; a camera device disposed on the 3D printer a state reporting module connected to the network information module and the photographic device for initiating the photographic device to take a photo of the printing device when a printing time meets the interval time, and using the network The information module transmits the photo and a print status value to the remote transceiver device; and a fixed format command receiving module is connected to the 3D printer for receiving a fixed format sent by the remote transceiver device Directing and parsing the fixed format instructions to manipulate the 3D printer.

[0017] In a US invention with patent number US9514397B2 which is granted dated 06 / 12 / 2016 titled “Printer monitoring” described techniques for monitoring a three-dimensional (3D) printer during the performance of a print job. An example of a system in accordance with the present techniques includes a camera to generate an image of a 3D print job in progress. The system also includes a baseline image generator to generate a baseline image based on a 3D model of the object to be printed. The system also includes a monitoring engine to compare the image with the baseline image to determine a status of the 3D print job and trigger an alarm if the 3D print job fails. The system can include one or more cameras, arranged at strategic locations around the building platform of the 3D printer. Images captured by the cameras can be processed and compared against a baseline image to determine whether the 3D print job is progressing as expected.

[0018] Another US invention with patent number US10265911B1 which is granted dated 23 / 04 / 2019 titled “Image-based monitoring and feedback system for three-dimensional printing” describes apparatuses and techniques for using an image-based monitoring and feedback system for three-dimensional printing. In some aspects, a camera captures images of objects being printed and an imageprocessing system compares the images with benchmark images to detect and correct differences between the object and the benchmark. The correction can be in real time or applied to subsequent printing. Other aspects include a calibration system that prints predefined test objects and compares them to benchmarks to ensure that the printer operating parameters are properly set. The comparison can be manually performed by a user or automated as a part of the image-processing system.

[0019] An US invention with patent number US 11189021B2 which is granted dated 30 / 11 / 2021 titled “Machine based three-dimensional (3D) object defect detection” describe systems and methods for machine based defect detection of three-dimensional (3D) printed objects. A method of one embodiment of the disclosure includes providing a first illumination of a 3D printed object using a first light source arrangement. A plurality of images of the 3D printed object is then generated using one or more imaging devices. Each image may depict a distinct region of the 3D printed object. The plurality of images may then be processed by a processing device using a machine learning model trained to identify one or more types of manufacturing defects of a 3D printing process. The machine learning model may provide a probability that an image contains a manufacturing defect. The processing device may then determine, without user input, whether the 3D printed object contains one or more manufacturing defects based on the results provided by the machine learning model.

[0020] In an US invention with patent number US9632037B2 which is granted dated 25 / 04 / 2017 titled “Three dimensional printing apparatus and method for detecting printing anomaly” a three dimensional printing apparatus and method for detecting printing anomaly are provided. The method is adapted to the three dimensional printing apparatus including an image sensor module and a movable platform. The three dimensional printing apparatus forms a plurality of layer objects on the movable platform according to three dimensional model information so as to build a three dimensional object including the layer objects. The method for detecting printing anomaly includes following steps. At least one object image is captured according to at least one view angle by using the image sensor module. At least one checking image associated with the layer objects is obtained according to the 3D model information and the view angle. Whether the object image and the checking image are matched to each other or not is determined through comparing the object image and the checking image.

[0021] Also in another US invention with publication number US20170057170A1 which is filed dated 28 / 08 / 2015 titled “Facilitating intelligent calibration and efficient performance of three-dimensional printers” a mechanism is described for facilitating intelligent calibration and efficient performance of three- dimensional printers according to one embodiment. A method of embodiments, as described herein, includes receiving a printing request for three-dimensional (3D) printing of a 3D object, and monitoring a printing process to print the 3D object, where the printing process is performed based on a reference design associated with the 3D object, the reference design including expected measurements associated with the 3D object. The method may further include computing, in real-time during the printing process, actual measurements relating to the 3D object, where the actual measurements are obtained via one or more 3D cameras. The method may further include comparing, in real-time, the actual measurements with the expected measurements to determine one or more measurement deficiencies caused by one or more errors encountered during the printing process, wherein, if the one or more errors are encountered, the one or more errors are compensated to facilitate the printing process to print the 3D object, and wherein, if no errors are encountered, the printing process continues to print the 3D object.

[0022] A 3D printing farm, also known as a 3D printing cluster or 3D printing service bureau, refers to a facility or setup where multiple 3D printers are organized and operated together to handle large-scale or high-volume 3D printing production. These facilities are designed to provide efficient and cost-effective manufacturing solutions for individuals, businesses, or organizations in need of large quantities of 3D printed parts or prototypes. A 3D printing farm consists of a network of 3D printers, often of the same or similar type, working simultaneously to produce multiple objects. 3D printing farms are particularly useful for businesses or individuals who require large quantities of prototypes, custom parts, or small-scale production runs without the need to invest in and manage their own fleet of 3D printers. They offer a cost-effective and streamlined solution for scaling up 3D printing production.

[0023] A 3D printing network, often referred to as a 3D printing service or 3D printing marketplace, is a platform that connects individuals or businesses in need of 3D printing services with 3D printing providers who can fulfill those needs. These platforms act as intermediaries, facilitating the process of ordering, producing, and delivering 3D printed objects. A network of 3D printing service providers who offer their printing capabilities to fulfill orders from customers. These providers may operate 3D printers with various technologies and materials. A web-based platform or marketplace where users can upload their 3D models, specify printing requirements, and place orders.

[0024] Among the remaining problems in network based printing of the files that are referred to 3D printer farms by applicants online is the presence of deformation and dimensional changes due to shrinkage and design bugs in the internal part of the volume.

[0025] DESCRIPTION OF THE INVENTION

[0026] The present invention is a type of network for receiving print orders based on artificial intelligence which the artificial intelligence server with the ability to leam and make decisions about choosing a printer, modifying software files and optimizing the printing process is in the first place of the innovation of the invention. In this invention, the nozzle of the printer head is equipped with a pressure switch that can measure the pressure required for the process during operation and provide a correct signal of the pressure of the printer head to the artificial intelligence about the polymer printers. Also, a network card is used as an external card next to old generation printers which can specify the printer of the present invention if it is not equipped with a network card, connected to a network platform and with specific IP.

[0027] The present invention is a smart 3D printer as well as a method and device for cleaning the nozzles in the printer head during the printing process and controlling cameras during printing. In the side part of the printer near the base, this invention is equipped with a kit containing needles of different sizes according to the size of the nozzle used in the printing process. Cleaning kits in 3D printers can help improve the performance and accuracy of printing, increase the life of parts and even reduce technical problems. One of the most important reasons for using cleaning kits is problems caused by unintentional blockages in printing. Since the materials used to print the desired model are constantly coming out of the nozzle in molten form, there is a possibility of clogging the nozzle and blocking the passage of the molten material. Therefore, the present invention includes a smart nozzle cleaning system that includes a kit containing 10 nozzle cleaning needles with different diameters according to the size of the nozzle opening. These cleaning kits are attached to a plate template and a stepper motor is connected to this plate and every time the motor rotates, the plate rotates 36 degrees. When a problem such as an unintentional blockage of the nozzle happen or when the pressure of the molten material increases due to the blockage of the exit channel, the exit of the material is stopped, this system works and the nozzle moves to the place where the cleaning needles are inserted and the stepper motor rotates according to the size of the nozzle opening and places the appropriate cleaning needle in the location of the nozzle hole, and the nozzle removes this unintentional blockage using a reciprocating motion.

[0028] Also, several cameras around the device and also near the nozzle are embedded in this invention to take videos or photos from different angles of the 3D printing process. Each of the 2 cameras installed around the nozzle has an LED, which can record videos in suitable lighting conditions and monitor the nozzle's performance when the nozzle cameras are working. In addition, 3 cameras with 4K quality are located around the smart printer. These 3 cameras are placed around the support base on the printer shaft to monitor the printing process. Also, for ease of filming and higher accuracy, the camera support base can be moved. The use of these cameras makes it possible to monitor the printing process online, and if an error occurs during printing, the user is notified and the printing process is stopped, and avoids problems such as model distortion and any possible defects after printing. Also, if there is an error in the final printed product, the recorded videos can be used to review the printing process and troubleshoot.

[0029] Given to equipping the available printers to the smart cleaning structure of the head and observing and monitoring cameras, at the time of sending a user's request to print a file, artificial intelligence first enters to the process and examines the content of the file and proceed to modify the file in case of existing a bug. Among the problems of 3D printing process are the plates and the internal structure of the part that result in strength or shaping of the part and this important issue caused the printed part mostly have deformation or more tolerance than done design.

[0030] Now, at the beginning of the process through imaging of the cameras and image processing process, the artificial intelligence can distinguish whether the deformation is in the normal range or the generated tolerance is more than normal range by comparing image dimensions with initial calibration. At this time, by calculating the polymer shrinkage after cooling of first layers of the print, if dimensional correction of the file is needed, and in order to reduce the tolerance caused by shrinkage or melt pressure coming out of the nozzle, the artificial intelligence enters to the process and exerts the required dimensional modifications or in case there is a need to create dimensions in the dividers and middle pages of the part, or if the need to redesign these pages is recognized by artificial intelligence, the mentioned file has been modified and thus the output part of the 3D printer is produced with a tolerance near to zero.

[0031] When the pressure of the molten material exiting the nozzle vary low and high, the artificial intelligence server can control the feed rate of the head or change the speed of the head movement or direct the device head to the cleaning unit and intelligently use the standard head needle to clean the head. Among the advantages of the mentioned system is equipping the printer with a smart multisize cleaning system.

[0032] Also, in another embodiment of this invention, a network of 3D printers can be considered as a 3D printing farm, in this way that the user will be able to find the closest 3D printing network to him in an online platform and by checking the types of printers available in that network, upload the desired model and the required information and register his print order in this platform. It should be noted that the printing process will be visible online by the cameras installed in the printers. After the printing process is finished, the desired model will be sent to the user.

[0033] BRIEF DESCRIPTION OF THE FIGURES

[0034] Figure 1 shows the smart 3D printer device printing an industrial model.

[0035] Figure 2 shows an overview of smart 3D printer which contains:

[0036] 201: Needle size 0.1 mm

[0037] 202: Needle size 0.2 mm

[0038] 203: Needle size 0.3 mm

[0039] 204: Needle size 0.4 mm

[0040] 205: Needle size 0.5 mm

[0041] 206: Needle size 0.6 mm

[0042] 207: Stepper motor holder plate

[0043] 208: stepper motor

[0044] 209: Needle size 0.7 mm 210: Needle size 0.8 mm

[0045] 211: Needle size 0.9 mm

[0046] 212: Needle size 1 mm

[0047] 213: connecting base of the camera to the shaft 214, 216, 218: 4K cameras

[0048] 215: Holder shafts of the cameras

[0049] 217: Monitoring cameras of the nozzles

[0050] Figure 3 shows a view of 4K cameras.

[0051] Figure 4 shows a view of the nozzle monitoring cameras along with the LEDs for each camera and the 3D printer nozzle which contains:

[0052] 401: Nozzle

[0053] 402: LED of the nozzle monitoring cameras

[0054] 403: Monitoring camera of the nozzle

[0055] Figure 5 shows a view of cleaning needles of the 3D printer nozzle. Figure 6 shows the manner of movement of the printer to clean the corresponding nozzle.

[0056] Figure 7 shows the manner of rotation of the needles by the stepper motor and the manner of cleaning the nozzle by the needle.

Claims

What is claimed is:

1. The invention of integrated system of polymer and metal 3D printing services of volumes equipped with artificial intelligence includes at least an artificial intelligence server and at least a 3D printer and at least a needle kit and at least a kit plate template and at least a stepper motor and at least one or more cameras placed around the printer and at least one or more cameras placed next to the nozzle and at least one LED and at least a support for the cameras and at least a pressure switch in the printer head nozzle and at least an external network card.

2. The system and 3D printing services of claim 1 which is a type of network for receiving print orders based on artificial intelligence3. The system and 3D printing services of claim 1 in which the artificial intelligence server is able to learn and make decisions about choosing a printer, modifying software files and optimizing the printing process.

4. The system and 3D printing services of claim 1 in which the nozzle of the printer head is equipped with a pressure switch that can measure the pressure required for the process during operation and provide a correct signal of the pressure of the printer head to the artificial intelligence about the polymer printers.

5. The system and 3D printing services of claim 1 in which a network card is used as an external card next to the old generation printers to connect the printer to the network platform with a specific IP.

6. The system and 3D printing services of claim 1 in which the 3D printer of the invention is equipped with a kit containing needles of different sizes.

7. The system and 3D printing services of claim 1 in which the cleaning kit contains at least 10 nozzle cleaning needles with different diameters according to the size of the nozzle opening.

8. The system and 3D printing services of claim 1 in which the cleaning kits are attached to a plate template.

9. The system and 3D printing services of claim 1 in which a stepper motor is connected to this plate and every time the motor rotates, the plate rotates 36 degrees.

10. The system and 3D printing services of claim 1 in which when the nozzle exit channel is blocked, the cleaning kit system operates and the nozzle moves to the place where the cleaning needles are inserted.

11. The system and 3D printing services of claim 1 in which the stepper motor rotates according to the size of the nozzle opening and places the appropriate cleaning needle in the location of the nozzle hole, and the nozzle removes this unintentional blockage using a reciprocating motion.

12. The system and 3D printing services of claim 1 in which 2 cameras are installed around the nozzle, each of which has a LED to create favorable light conditions for filming.

13. The system and 3D printing services of claim 1 in which 3 cameras with 4K quality are located around the smart printer, which are placed around the support base to the shaft installed on the printer.

14. The system and 3D printing services of claim 1 in which it is possible to monitor the printing process online.

15. The system and 3D printing services of claim 1 in which first, artificial intelligence enters the process and examines the content of the file and corrects the file if there is a bug.

16. The system and 3D printing services of claim 1 which can be presented in the form of a network of 3D printers in an online platform.

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