3D Fabrication Layer Feedback Control for Thermal Deformation
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Solution Overview
Problem
Existing 3D fabrication methods, such as FFF and SLS, often result in thermal deformation issues like shrinkage or warpage due to cooled fabrication materials, leading to low fabrication accuracy and the need for materials with minimal thermal deformation, which is not always feasible.
Innovation Solution
A fabricating apparatus and method that incorporates a shape sensor to measure each fabrication layer, compares the measured data with pre-defined fabrication data, and corrects the fabrication parameters in real-time to adjust for errors, ensuring accurate layer formation and minimizing thermal deformation effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional 3D fabrication methods (FFF, SLS) are used, then fabrication process is simple, but thermal deformation (shrinkage, warpage) occurs leading to low fabrication accuracy
Solution Approach 1:
The patent implements a feedback control system where a shape sensor measures the actual shape of each fabricated layer, the controller compares measured data with target data, and adjusts fabrication parameters for subsequent layers based on detected deviations. This closed-loop feedback mechanism compensates for thermal deformation in real-time, achieving high fabrication accuracy without requiring specialized materials.
Solution Approach 2:
The system performs preliminary measurement of each fabricated layer before proceeding to the next layer. By measuring the actual shape immediately after fabrication and using this information to adjust subsequent fabrication parameters, the system proactively compensates for thermal deformation effects before they accumulate, maintaining overall fabrication accuracy.
2Manufacturing precision
If materials with minimal thermal deformation are used, then fabrication accuracy is improved, but material selection is limited and not always feasible
Solution Approach 1:
The patent changes the control parameters of the fabrication process dynamically based on measured deviations. By adjusting fabrication parameters (such as laser power, scanning speed, or deposition rate) in response to real-time shape measurements, the system compensates for thermal deformation effects without being constrained by material properties, allowing use of conventional materials with high flexibility.
3Manufacturing precision
If real-time measurement and correction is implemented, then fabrication accuracy is enhanced, but measurement and control complexity increases
Solution Approach 1:
The fabrication system performs self-correction by automatically measuring its own output with a shape sensor and adjusting its own fabrication parameters based on measured deviations. The controller enables the fabrication device to self-regulate the fabrication process without external intervention, compensating for thermal deformation through autonomous feedback control, thereby achieving high accuracy while managing measurement and control complexity through automation.
Data Source
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AI summary
A fabricating apparatus (100) includes a fabricating device (206), a sensor (207), and a controller (330). The fabricating device (206) is configured to fabricate a fabrication layer according to fabrication data of a three-dimensional object. The sensor (207) is configured to measure a shape of the fabrication layer. The controller (330) is configured to control the fabricating device (206) according to the fabrication data and the shape of the fabrication layer measured with the sensor (207).