3D Printing Deformation Control via Real-Time Beam Adjustment
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Solution Overview
Problem
During 3D printing, layers of the printed object can deform, warp, or curl, making it challenging to control the formation of the object in real-time and achieving a desired shape without auxiliary supports or deformations.
Innovation Solution
A system and method that uses a controller to detect and control the deformation of 3D objects by adjusting the energy beam's power, temperature, and curvature during the printing process, allowing for the formation of objects with controlled deformation, smooth surfaces, and reduced warping, using a powder bed and energy beam to transform and shape the material layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If layers are deposited in successive material-layers to form a 3D object, then the object can be built up layer by layer, but the layers may bend, warp, roll, or curl during the printing process
Solution Approach 1:
The system performs preliminary actions by projecting the energy beam pattern onto the construction zone before actual material consolidation occurs. This allows detection and control of potential deformations before they affect the final layer quality, enabling preventive adjustment of printing parameters to maintain layer flatness while preserving deposition speed
Solution Approach 2:
The system implements feedback control by continuously monitoring the construction zone with the energy beam pattern, detecting deformations as they occur, and using this information to adjust subsequent layer deposition parameters. This closed-loop approach maintains layer flatness without sacrificing productivity by dynamically adapting the printing process based on real-time conditions
2Strength
If the energy beam power is increased to improve layer consolidation, then material bonding improves, but layer deformation and warping increase
Solution Approach 1:
The system applies local quality by using a patterned energy beam that consolidates material only in specific locations where needed, rather than uniformly across the entire layer. This selective consolidation approach strengthens bonds in critical areas while minimizing thermal input in other regions, thereby reducing warping and deformation while maintaining necessary layer bonding strength
Solution Approach 2:
The system dynamically changes energy beam parameters (power, duration, pattern) based on real-time detection of layer formation conditions. By adjusting these parameters locally and temporally, the system optimizes the balance between achieving sufficient layer bonding strength and minimizing thermal-induced deformations, allowing strong bonds where needed without excessive warping
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 the generation of 3D objects with precise control over deformation, eliminating the need for auxiliary supports and achieving smooth, planar surfaces by dynamically adjusting the energy beam parameters in real-time, resulting in objects that closely match the desired model.
Implementation Method 1
an energy beam to transform at least a portion of the first layer of powder material to form a first transformed material portion
Implementation Method 2
selective laser sintering (SLS), direct metal laser sintering (DMLS)
Implementation Method 3
deforming the multi layered object to comprise a curvature, which curvature is measured and controlled during the transforming
Data Source
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AI summary
The present disclosure provides three-dimensional (3D) printing method and apparatuses using, inter alia, a controller (that regulates formation of at least one 3D object (e.g., in real time during the 3D printing); and a non-transitory computer-readable medium facilitating the same. For example, a controller that regulates a deformation of at least a portion of the 3D object. The control may be in situ control. The control may be real-time control during the 3D printing process. An example of a 3D is printer (360), where the radiation (320) is projected from the exposed surface (308) of the material bed (304) towards the ceiling of the enclosure (300) and detected in the sensor part (318). For example, the control may be during a phenomenon pulse.