3D Print Measurement Locations for Deviation-Aware Reprinting
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Solution Overview
Problem
Conventional 3D printing technologies face challenges in accurately identifying and correcting imperfections in printed products, leading to potential system downtime, damage, or safety issues due to deviations from design specifications, as in-process correction methods do not effectively address internal and external imperfections and lack information for re-print strategies.
Innovation Solution
A system comprising a processor and memory that receives design information, generates measurement locations, performs measurements using a measurement device, compares data to design specifications, identifies deviations, and generates correction information for re-printing, incorporating a laser scanner to measure and correct positioning errors in a 3D printing system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If in-process correction is used to reduce imperfections during printing, then the printed product has reduced imperfections, but the already-printed portions contain defects that render the entire product defective
Solution Approach 1:
The system performs preliminary measurement and deviation identification before the printing process completes, allowing correction information to be generated in advance. This enables the entire printing process to be adjusted based on predicted deviations rather than attempting correction after defects are already present in printed portions.
Solution Approach 2:
The system implements a feedback mechanism where measurement data from the printed object is compared to design information, deviations are identified, and correction information is generated to adjust subsequent printing operations. This closed-loop feedback ensures that deviations are systematically addressed rather than merely reduced.
2Loss of time
If conventional measurement methods are used, then measurement time is reduced, but internal and external imperfections cannot be accurately identified
Solution Approach 1:
The measurement system is designed to perform multiple functions: measuring both external dimensions and internal characteristics, identifying various types of imperfections, and generating comprehensive deviation information. This multi-functional approach eliminates the need for separate measurement processes for different defect types.
Solution Approach 2:
The system uses an intermediary measurement device that captures comprehensive data about the printed object's geometry and characteristics. This intermediary measurement data serves as a bridge between the printed object and the correction process, enabling accurate identification of both internal and external imperfections without requiring direct physical intervention.
3Manufacturing precision
If in-process correction is implemented, then printing errors are reduced during the process, but no information is provided about the extent and location of imperfections for re-print operations
Solution Approach 1:
The system generates comprehensive feedback information that includes not only correction instructions but also detailed data about the location, extent, and nature of deviations. This feedback loop provides complete information about imperfections, enabling both in-process correction and informed re-print decisions.
Solution Approach 2:
The correction information is segmented and organized by location and type of deviation, providing detailed spatial and categorical breakdown of imperfections. This segmentation allows users to understand exactly where and what kind of corrections are needed, rather than receiving generic correction instructions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables precise identification and correction of imperfections, ensuring printed products meet design specifications, reducing re-print needs, and improving the accuracy and reliability of 3D printing processes.
Implementation Method 1
generate a measurement strategy for performing measurement of the set of measurement locations by the measurement device... receive measurement data corresponding to the measurement locations measured according to the measurement strategy
Data Source
AI summary
A method of 3D printing an object includes receiving design information corresponding to an object for which a printed object is to be generated by a 3D printing operation according to a first set of print instructions, generating a plurality of measurement locations, printing successive layers which form the object, measuring the object at the measurement locations to form measurement data, comparing the measurement data with expected measurements of the measurement locations based on the design information, and generating, based on the comparing, deviation information. The measurement locations represent locations of the object to be measured by a measurement device. The deviation information represents deviations between the printed object following completion of the printing, and the object represented by the design information.