3D Print Measurement Locations for Deviation Detection and Re-Print
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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
An apparatus and method that incorporates a processor and memory to receive design information, generate measurement locations, perform measurements using a device like a laser scanner, compare measurement data to design specifications, and generate deviation information to correct positioning and re-print strategies, ensuring accurate alignment and composition of 3D-printed parts.
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 analysis of imperfections before final product acceptance, using measurement devices to scan and identify defects in already-printed portions. This allows the system to detect issues early and determine whether re-printing is necessary, rather than waiting until the end of the printing process.
Solution Approach 2:
The system implements a feedback loop where measurement data from scanned imperfections is fed back into the printing process control. The controller uses this information to adjust printing parameters or trigger re-printing operations, ensuring that products meeting specification tolerances are accepted while defective products are identified and re-printed.
2Productivity
If conventional 3D printing is used without comprehensive measurement, then the printing process is simple and fast, but imperfections in internal structure and composition cannot be identified
Solution Approach 1:
The measurement system is designed to perform multiple functions: scanning external surfaces, detecting internal structural imperfections, analyzing material composition, and providing data for both quality control and process optimization. This multi-functional approach allows comprehensive inspection without requiring multiple separate devices.
Solution Approach 2:
The system uses measurement devices as intermediaries between the printed product and the control system. These devices capture detailed information about imperfections and transmit this data to the controller, which then uses the information to make informed decisions about product acceptance or re-printing, bridging the gap between physical inspection and digital control.
3Manufacturing precision
If in-process correction identifies and corrects printing errors, then ongoing printing errors are minimized, but information about the extent and location of imperfections is not provided
Solution Approach 1:
The system implements comprehensive feedback that not only corrects printing errors in real-time but also provides detailed information about the location, extent, and nature of imperfections. Measurement data is fed back to the controller with precise spatial coordinates and defect characteristics, enabling both correction and documentation of issues.
Solution Approach 2:
The system creates detailed digital copies or models of the printed product including recorded imperfection data. This digital twin contains information about the location and extent of all detected defects, preserving this information for analysis, traceability, and use in subsequent re-printing operations without losing any measurement details.
4Measurement precision
If measurement devices are incorporated with 3D printers to identify imperfections, then accurate correction information can be determined, but the device complexity increases
Solution Approach 1:
The system merges the measurement devices with the 3D printer into an integrated unit. The measurement scanner, controller, and printing mechanism are combined in a single system, allowing seamless coordination between measurement and printing operations. This integration reduces the need for separate standalone devices and simplifies the overall system architecture.
Solution Approach 2:
The integrated system performs multiple functions within a single apparatus: 3D printing, real-time measurement, imperfection detection, data analysis, and control. This multi-functionality eliminates the need for separate dedicated devices for each operation, reducing overall system complexity while maintaining high measurement precision.
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 3D-printed products meet design specifications, reducing the risk of system downtime and safety hazards by providing detailed deviation information for re-printing, thus enhancing the geometric robustness and accuracy of 3D-printed parts.
Implementation Method 1
measuring the object at the measurement locations to form measurement data
Implementation Method 2
measured by a measurement device
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.