3D Printer Process Capability Analysis via Segmented Build Regions
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Solution Overview
Problem
In industrial manufacturing, especially with 3D printing, there is a need for efficient process capability studies to determine optimal production parameters for additive manufacturing machines, as extensive testing is required to ensure products meet tolerance limits and maintain consistent quality over time.
Innovation Solution
A method involving a data processing apparatus that receives and analyzes variable process parameters for 3D printing jobs, allowing for the generation of process capability data by printing objects with different parameter settings within a 3D printer's build volume, enabling the determination of ideal parameter values for producing high-quality three-dimensional objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If extensive testing with a significant range of parameter variations is conducted to determine process capability, then manufacturing precision and reliability are improved, but loss of time and productivity decrease
Solution Approach 1:
The patent segments the build volume into multiple distinct regions, each designated for testing specific parameter variations. This allows simultaneous evaluation of multiple process conditions in a single build, reducing the number of separate tests required while maintaining comprehensive process capability analysis
Solution Approach 2:
The patent combines multiple test objects with different parameter variations into a single build job. By merging these tests into one consolidated build, the system achieves extensive parameter evaluation without the time penalty of sequential testing, thus improving productivity while maintaining manufacturing precision
2Manufacturing precision
If multiple parameter variations are tested to determine optimal process values, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system segments the complexity management by assigning specific parameter variations to specific build regions. This organizational structure simplifies the tracking and analysis of parameter effects, making the complex testing process more manageable without compromising the depth of process optimization
Solution Approach 2:
The patent uses digital models and data structures to represent and manage parameter variations, rather than requiring complex physical reconfiguration for each test. This digital copying approach reduces device complexity while enabling comprehensive parameter evaluation for process optimization
3Reliability
If process capability studies are conducted thoroughly to ensure tolerance compliance, then reliability is improved, but productivity decreases
Solution Approach 1:
The patent merges multiple reliability verification tests into a single build operation. By evaluating tolerance compliance across multiple parameter sets simultaneously in one build, the system maintains thorough reliability assessment while avoiding the productivity loss associated with sequential testing
Solution Approach 2:
The system segments the reliability analysis into distinct build regions, each targeting specific tolerance requirements. This allows parallel evaluation of different tolerance scenarios without requiring separate production runs, thereby maintaining productivity while ensuring comprehensive tolerance compliance
Data Source
AI summary
Example implementations relate to process capability procedures for additive manufacturing machines. One example implementation receives and prints two objects with corresponding process values for a set of process parameters within two build regions of the build volume. Measurements are made of each object comprising print parameters and a dataset comprising data representing the process values associated with the print parameters and data representing the second process values associated with the second print parameters is generated.