3D Model Compensation for Additive Manufacturing Dimensions
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Solution Overview
Problem
Additive manufacturing techniques face challenges in achieving accurate dimensional consistency due to material growth or shrinkage during the solidification process, leading to deviations in object dimensions, which existing geometrical compensation models fail to adequately address, especially for external, internal, and non-surface dimensions.
Innovation Solution
A method involving a geometrical compensation model that categorizes dimensions into types (external, internal, and non-surface) and applies specific scaling factors and offset values to modify object model data, using processor-based algorithms to determine and apply these corrections, ensuring improved dimensional accuracy by considering the distinct behaviors of each dimension category.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing geometrical compensation models are used, then manufacturing process is simple, but manufacturing precision deteriorates due to inadequate compensation for external, internal, and non-surface dimensions
Solution Approach 1:
The patent segments dimensions into three distinct categories: external dimensions, internal dimensions, and non-surface dimensions. Each category is compensated using dedicated scaling factors and offset values. This segmentation allows the system to address the specific compensation needs of each dimension type independently, resolving the contradiction by improving overall dimensional accuracy through targeted compensation while maintaining a structured, manageable model framework.
Solution Approach 2:
The patent applies local quality by assigning different compensation parameters (scaling factors and offset values) to different dimension categories based on their specific characteristics. External dimensions receive one set of compensation parameters, internal dimensions receive another set, and non-surface dimensions receive a third set. This localized compensation approach ensures that each dimension type is corrected according to its specific deviation patterns, thereby improving manufacturing precision without requiring a single overly complex universal model.
2Manufacturing precision
If material growth or shrinkage during solidification is not compensated, then manufacturing process is simple, but manufacturing precision deteriorates due to dimensional deviations
Solution Approach 1:
The patent implements preliminary action by calculating and applying compensation values to the 3D model data before the additive manufacturing process begins. The system determines scaling factors and offset values for each dimension category in advance, based on anticipated material growth or shrinkage during solidification. This pre-compensation approach addresses dimensional deviations before they occur, improving dimensional consistency while avoiding the need for complex real-time adjustments during manufacturing.
Solution Approach 2:
The patent employs feedback mechanisms by using measured deviations from previously manufactured objects to refine compensation parameters for subsequent manufacturing runs. The system analyzes actual dimensional deviations in external, internal, and non-surface dimensions from past production, updates the scaling factors and offset values accordingly, and applies these improved parameters to future 3D models. This feedback loop continuously improves manufacturing precision while maintaining a systematic compensation framework.
Data Source
AI summary
An example method includes obtaining, by at least one processor, a plurality of categorised indications of deviations from expected dimensions for at least one object generated using an additive manufacturing apparatus wherein the categories comprise at least two of a first dimension type comprising dimensions which are expected to increase on application of a positive offset to object model data used to generate an object, a second dimension type comprising dimensions which are expected to decrease on application of a positive offset to the object to object model data used to generate an object, and a third dimension type comprising dimensions which are expected to be unaffected by application of an offset to object model data used to generate an object. The method may include determining a geometrical compensation model to apply to object model data for generating objects using additive manufacturing to compensate for anticipated deviations in dimensions.