3D Printed Object Data Overlay for Non-Destructive Defect Analysis
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Solution Overview
Problem
Existing methods for testing and evaluating manufactured objects, such as three-dimensionally printed items, often involve destructive processes or irreversible changes, making it difficult to diagnose defects and determine the relationship between design or manufacturing parameters and resulting properties, and require numerous iterations to optimize production.
Innovation Solution
A system comprising an identification engine, alignment engine, and rendering engine that overlays production data onto the manufactured object using augmented reality, allowing for non-destructive analysis and visualization of production data, enabling efficient diagnosis of defects and optimization of manufacturing parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If destructive testing methods are used to evaluate manufactured objects, then defect detection capability is improved, but the manufactured object is damaged or destroyed
Solution Approach 1:
The patent uses augmented reality to create a virtual copy of the manufacturing process and production data that overlays on the physical object. Instead of physically testing the object, the system generates and displays a digital twin showing temperature distributions, material properties, and process parameters, allowing defect detection without damaging the actual manufactured object.
Solution Approach 2:
The patent introduces an augmented reality display system as an intermediary between the physical object and the analysis process. The AR headset displays virtual production data and visualizations that mediate the inspection process, enabling non-destructive defect detection by showing thermal maps, stress distributions, and manufacturing parameters overlaid on the object's surface.
2Manufacturing precision
If multiple physical iterations are manufactured to optimize production parameters, then manufacturing optimization is improved, but time consumption and resource usage increase
Solution Approach 1:
The patent captures and stores production data (temperature, material composition, process parameters) during the manufacturing process itself. This preliminary capture of data allows for later analysis and optimization without requiring additional physical iterations, as the original production conditions are preserved and can be reviewed, analyzed, and adjusted through the AR interface.
Solution Approach 2:
The system provides immediate visual feedback through augmented reality displays showing production data and quality metrics overlaid on the manufactured object. This real-time or near-real-time feedback loop allows manufacturers to identify issues and adjust parameters without waiting for destructive testing results, reducing the need for multiple physical iterations.
3Loss of information
If comprehensive production data is collected during manufacturing, then analysis capability is improved, but data management complexity increases
Solution Approach 1:
The patent merges the physical manufacturing process with digital data collection and visualization. The augmented reality system combines production data from multiple sensors and sources into a unified visual representation that overlays on the physical object, simplifying data management by presenting all relevant information in a single integrated view rather than separate data sets.
Data Source
AI summary
An example system includes an identification engine to determine production data associated with a three-dimensionally printed object. The system also includes an alignment engine to determine a placement of the three-dimensionally printed object relative to a display device. The system includes a rendering engine to generate an image including a visual representation of the production data. The rendering engine is to position the visual representation of the production data so that representations of data points in the production data will overlay corresponding portions of the three-dimensionally printed object upon displaying by the display device.