3D Printer Bed Scanning for In-Process Toolpath Compensation
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Solution Overview
Problem
Current 3D printing technologies lack effective methods for in-process inspection and calibration of the print bed and deposited materials, leading to inaccuracies and inconsistencies in the printed parts due to manufacturing deviations and environmental factors.
Innovation Solution
A method involving a rangefinding scanner and a shared carriage with a print material deposition head for in-process inspection and calibration, which generates a compensation array to adjust toolpaths and ensure accurate deposition on an imperfect print bed, using a rangefinding scanner to measure surface profiles and compare them with predefined toolpaths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional 3D printing methods are used without in-process inspection, then the printing process is simpler and faster, but the manufacturing precision and consistency of printed parts deteriorate due to print bed imperfections and environmental factors
Solution Approach 1:
The patent replaces complex mechanical measurement systems with optical sensing. A camera mounted on the print head captures images of the print bed surface, and image processing algorithms automatically detect surface deviations. This optical approach eliminates the need for complex mechanical contact measurement devices while achieving high precision calibration.
Solution Approach 2:
The system performs self-calibration by automatically capturing images of the print bed, processing these images to identify surface deviations, and generating compensation data without requiring external inspection equipment or manual measurement. The printing system inspects and calibrates itself autonomously.
2Manufacturing precision
If in-process inspection with rangefinding scanner is implemented, then the manufacturing precision and consistency improve, but the device complexity and measurement time increase
Solution Approach 1:
The inspection process is integrated into the printing workflow such that the camera captures images during normal printing operations or between layers. The image processing and compensation data generation occur continuously or near-real-time, eliminating separate inspection steps and maintaining continuous productive action.
Solution Approach 2:
The patent introduces an image processing algorithm as an intermediary between the camera and the printing system. This intermediary automatically extracts surface deviation information from images and generates compensation data, significantly reducing the time required compared to manual measurement and calculation methods.
3Manufacturing precision
If compensation arrays are generated and applied to adjust toolpaths, then the manufacturing precision improves by compensating for deviations, but the device complexity and computational requirements increase
Solution Approach 1:
The system dynamically adjusts printing parameters (toolpath coordinates, deposition height, head position) based on the compensation array generated from image analysis. These parameter changes are applied automatically by the printing system to counteract detected print bed deviations, achieving high dimensional accuracy without complex physical modifications.
Solution Approach 2:
The compensation array is generated and applied before the actual printing process begins, or between layers during printing. This preliminary adjustment of toolpaths ensures that all subsequent deposition operations account for print bed imperfections, preventing rather than correcting errors.
4Reliability
If real-time scanning and comparison of surface profiles with toolpaths is performed, then the reliability and quality control improve, but the productivity and printing speed decrease
Solution Approach 1:
The system performs inspection selectively rather than continuously throughout the entire printing process. Images are captured at key moments (before printing, between layers, or at critical sections), and processing is performed only on these selected frames. This partial inspection approach maintains quality control while minimizing impact on printing throughput.
Solution Approach 2:
The patent implements rapid image capture and processing techniques that skip unnecessary measurement steps. The camera captures images at high speed, and the image processing algorithm uses efficient algorithms to quickly extract essential deviation information, rushing through the inspection process to minimize interruption of printing operations.
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 real-time monitoring and adjustment of the printing process, compensating for manufacturing deviations and environmental changes, resulting in improved accuracy and consistency of the printed parts.
Implementation Method 1
A scanned surface profile of a printing material shell may be received, together with the identification, from the 3D printer
Implementation Method 2
A method involving a rangefinding scanner and a shared carriage with a print material deposition head for in-process inspection and calibration
Data Source
AI summary
In in-process inspection or calibration of a print bed or 3D printed part with a 3D printer, toolpaths defining printing material shells for deposition by a 3D printer are compared to surface profile scans from a range scanner to identify differences between the print bed, instructed deposition and the measured result, permitting pausing or alteration of the toolpaths or printing process.