3D Lattice Adjustments for Build-Bed Uniformity
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Solution Overview
Problem
Additive manufacturing machines face challenges in achieving uniformity of mechanical properties and geometric attributes across different build regions of a build bed, leading to poor yields and unpredictability in 3D parts due to non-uniformity in lattice structures.
Innovation Solution
A lattice adjustment engine applies adjustment factors to lattice structures by modifying geometric properties such as size, shape, and node positions without changing beam thickness, followed by adding beam thickness to ensure consistent mechanical properties across the build bed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additive manufacturing machines build layers uniformly across the build bed, then manufacturing precision should be consistent, but non-uniformity in lattice structures causes poor yields and unpredictability
Solution Approach 1:
The patent applies different adjustment factors to different build regions of the build bed. The system determines that certain regions require lattice structure adjustments while others do not, creating localized modifications to achieve uniformity across the entire build bed. This regional differentiation allows compensation for machine-specific non-uniformities without requiring global changes to all parts.
Solution Approach 2:
The system modifies lattice structure parameters (such as beam dimensions, node positions, or unit cell geometry) based on determined adjustment factors. By changing these geometric parameters selectively in different build regions, the system compensates for manufacturing non-uniformities and achieves consistent mechanical properties across all parts.
2Manufacturing precision
If adjustment factors are applied to lattice structures to compensate for non-uniformities, then manufacturing precision improves, but the complexity of the build process increases
Solution Approach 1:
The system determines adjustment factors before the actual manufacturing process begins. By pre-calculating the necessary lattice structure modifications for each build region and incorporating them into the digital model beforehand, the system eliminates the need for complex real-time adjustments or post-processing, thereby reducing overall process complexity while maintaining precision.
3Ease of manufacture
If beam thickness is kept constant during lattice adjustments, then manufacturing simplicity is maintained, but mechanical property uniformity deteriorates
Solution Approach 1:
The system applies adjustment factors that modify specific lattice parameters (such as beam length, node positions, or unit cell dimensions) while keeping beam thickness constant in regions where this approach suffices. This localized parameter modification maintains manufacturing simplicity while achieving the necessary mechanical property uniformity.
Data Source
AI summary
In some examples, a system applies a first adjustment factor to a first representation of a first lattice structure of a first three-dimensional (3D) part to generate a first adjusted representation of the first lattice structure, the first representation comprising a representation of beams of the first lattice structure without a thickness. The system applies a second adjustment factor to a second representation of a second lattice structure of a second 3D part to generate a second adjusted representation of the second lattice structure, the second representation comprising a representation of beams of the second lattice structure without a thickness. The system adds beam thicknesses to the first and second adjusted representation to provide respective digital models of the first and second 3D parts that are useable by an additive manufacturing machine in building the first and second 3D parts in respective build regions of a build bed.