3D Object Model Compensation for Additive Manufacturing Accuracy
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Solution Overview
Problem
Additive manufacturing techniques face challenges in achieving dimensional accuracy due to material growth or shrinkage during the thermal fusing process, leading to inconsistencies between intended and generated object sizes.
Innovation Solution
A method involving geometrical compensation vectors is applied to object model data, using scaling and offset factors to adjust the dimensions of the object model, which involves a processor-based process to determine and apply these vectors based on orthogonal axes, material properties, and object location, ensuring accurate object generation by modifying the object model data through Hadamard products and scalar projections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermal fusing process is used to generate objects layer-by-layer, then three-dimensional objects can be created through solidification of build material, but dimensional accuracy deteriorates due to material growth or shrinkage during the process
Solution Approach 1:
The patent applies geometrical compensation vectors to the object model data before manufacturing to pre-correct for anticipated dimensional deviations. By calculating and applying compensation factors based on the object's location, orientation, and material properties beforehand, the system counteracts the expected growth or shrinkage that will occur during thermal fusing, thereby maintaining dimensional accuracy while preserving the additive manufacturing process benefits
2Manufacturing precision
If geometrical compensation is applied to object model data, then dimensional accuracy is improved, but computational complexity increases due to vector calculations and model modifications
Solution Approach 1:
The patent transforms the complex geometrical compensation problem into a parameter-based solution by defining compensation vectors with scaling and offset factors along orthogonal axes. Instead of performing complex geometric transformations, the system applies simple parameter adjustments (scaling factors and offset values) to the object model data, significantly reducing computational complexity while maintaining dimensional accuracy improvement
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 significantly improves dimensional accuracy by compensating for growth and shrinkage, ensuring the generated objects are closer to their intended size, with enhanced resolution and computational efficiency.
Implementation Method 1
the solidification method may include heating the layers of build material to cause melting in selected regions
Implementation Method 2
Additive manufacturing techniques may generate a three-dimensional object through the solidification of a build material
Implementation Method 3
material growth or shrinkage during the thermal fusing process
Implementation Method 4
material growth or shrinkage during the thermal fusing process
Data Source
AI summary
In an example, a method includes receiving, at least one processor, object model data representing at least a portion of an object that is to be generated by an additive manufacturing apparatus by fusing build material within a fabrication chamber, wherein the object model data comprises a mesh model comprising data describing a surface of the object. A geometrical compensation vector may be determined for the object model data, the geometrical compensation vector having a first component applying to a first axis of the fabrication chamber and a second component applying to a second axis of the fabrication chamber. A geometrical compensation to apply to at least one location on the surface of the object may be determined by determining a product of the geometrical compensation vector and a vector indicative of the normal of the object surface at the location and the determined geometrical compensation may be applied to the object model data to generate modified object model data.