3D Print Measurement Feedback for Defect Correction
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Solution Overview
Problem
Conventional 3D printing technologies fail to accurately identify and correct both external and internal imperfections in printed products, leading to deviations from design specifications, which can result in poor fitment, durability issues, and potential safety hazards.
Innovation Solution
An apparatus and method that incorporates a processor, memory, and a measurement device, such as a laser scanner, to receive design information, generate measurement locations, and compare measurement data to design specifications, identifying deviations and generating correction information for re-printing strategies.
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 product still contains defects that make it unacceptable for critical industrial applications
Solution Approach 1:
The system performs preliminary measurement and defect identification during the printing process, allowing correction information to be generated and applied to subsequent printing operations. This preliminary detection enables the system to prevent defects rather than merely reduce them, ensuring critical components meet strict industrial specifications.
Solution Approach 2:
The system implements a closed-loop feedback mechanism where measurement data from the printed object is continuously compared against design specifications, and correction information is fed back to adjust the printing process. This real-time feedback ensures that any deviations are immediately corrected, guaranteeing product reliability for critical applications.
2Measurement precision
If measurement devices are incorporated with 3D printers to identify imperfections, then accurate defect identification is achieved, but the device complexity increases
Solution Approach 1:
The system merges the measurement device with the 3D printer into an integrated platform, allowing simultaneous printing and measurement operations. This consolidation achieves high measurement precision while managing system complexity through unified hardware and software architecture.
Solution Approach 2:
The measurement device is designed to perform multiple functions including defect detection, dimensional verification, and surface quality assessment. This multi-functionality justifies the added complexity by providing comprehensive quality control capabilities that exceed simple defect identification.
3Manufacturing precision
If re-printing operations are performed to eliminate imperfections, then imperfection-free products are achieved, but the loss of time increases
Solution Approach 1:
The system performs preliminary defect identification and generates correction information during the initial printing process, allowing adjustments to be made before completing the entire print job. This prevents the need for complete re-printing, significantly reducing time loss while ensuring imperfection-free final products.
Solution Approach 2:
The system dynamically adjusts the printing process based on real-time measurement feedback, modifying print parameters and correction strategies adaptively. This dynamic approach optimizes the balance between achieving high manufacturing precision and minimizing time loss by correcting only the necessary portions.
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
Enables accurate identification and correction of imperfections, ensuring printed products meet design specifications, reducing the risk of system downtime, physical injury, or damage, and improving overall product quality.
Implementation Method 1
a measurement device, such as a laser scanner
Data Source
Figure 1A
Figure 1B
Figure 2
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 (14), 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.