3D Printer Scanner for Real-Time Defect Rectification
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Solution Overview
Problem
Existing additive manufacturing systems lack effective evaluation methods to detect defects in 3D objects during production, leading to potential inaccuracies and poor quality prints, as errors may not be observable until later layers are formed, and previous systems do not adequately address these issues.
Innovation Solution
A method and system that utilize a scanner to generate a data file of the produced 3D object, comparing it with a reference data file used for printing, identifying differences, and rectifying defects by adjusting the production process, incorporating a controller and ejector system to produce the object on a planar member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional subtractive manufacturing processes are used, then manufacturing precision can be achieved for small quantities, but productivity and adaptability for complex 3D shapes are limited
Solution Approach 1:
The patent replaces traditional mechanical subtractive manufacturing processes with an additive manufacturing system that uses digital modeling and automated material deposition. The system substitutes manual or mechanical cutting operations with computer-controlled ejector heads that deposit material layer by layer according to digital specifications, enabling complex geometries without the limitations of subtractive methods
Solution Approach 2:
The patent implements real-time monitoring and adjustment of manufacturing parameters during the additive production process. The system continuously measures physical characteristics of deposited layers and automatically adjusts deposition parameters such as material flow rate, heating temperature, and layer thickness to maintain manufacturing precision while maximizing productivity
2Productivity
If additive manufacturing is used to produce complex 3D objects, then productivity and design flexibility improve, but defects may occur that are undetectable until later layers are formed
Solution Approach 1:
The patent incorporates preliminary quality assurance by implementing real-time defect detection during the additive manufacturing process. The system continuously monitors each layer as it is deposited, identifying defects such as improper material deposition, layer delamination, or dimensional deviations before subsequent layers are formed, allowing immediate corrective action to prevent propagation of errors
Solution Approach 2:
The patent implements a closed-loop feedback system where the output of each manufacturing layer is measured and compared against digital specifications in real-time. The system uses sensors to detect deviations in material properties, layer thickness, and geometric accuracy, then automatically feeds this information back to adjust the deposition process parameters to maintain production quality and reliability
3Reliability
If real-time evaluation systems are implemented to detect defects, then production quality improves, but device complexity increases
Solution Approach 1:
The patent implements multi-functional components that perform multiple operations simultaneously. The additive manufacturing system integrates material deposition, layer curing, real-time sensing, and quality evaluation functions into a unified platform. The same actuators and sensors used for normal operation are leveraged for quality assessment, reducing the need for separate dedicated inspection equipment and minimizing overall system complexity
Data Source
AI summary
A method for evaluating a three-dimensional (3D) object produced by a three-dimensional (3D) object printer includes generating with a scanner a first data file of the 3D object produced by the three-dimensional object printer. The first data file includes data corresponding to an interior surface and an exterior surface of the 3D object. The method further includes comparing the first data file with a second data file. The second data file is used to operate the three-dimensional object printer to produce the 3D object. The method further includes identifying differences between the first data file and the second data file and identifying a process to rectify a defect on the 3D object based on the identified differences to enable evaluation of the production of the 3D object by the three-dimensional object printer.