3D Printing Fault Detection With In-Process Material Removal
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Solution Overview
Problem
Conventional 3D printing systems lack the ability to detect and correct errors or defects during the printing process, leading to wasted time and material, as they cannot interact with the object being printed and often exacerbate defects in subsequent layers.
Innovation Solution
The implementation of sensors to monitor the 3D printing process, detect defects in the partially completed object, and correct them by removing unwanted material using tools like drills or grinders, allowing for real-time adjustments to ensure the final product meets the desired size and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional 3D printing systems continuously deposit material layers without interruption, then productivity is improved, but manufacturing precision deteriorates due to undetected and unc corrected errors in subsequent layers
Solution Approach 1:
The system performs preliminary detection and correction of errors in previously deposited layers before continuing to deposit new layers. The sensor scans completed layers and the correction tool removes unwanted material in advance, preventing error propagation to subsequent layers while maintaining continuous printing productivity
Solution Approach 2:
The system implements real-time feedback by continuously scanning deposited layers with sensors, comparing actual geometry against the digital model, detecting deviations, and automatically triggering correction actions. This closed-loop feedback mechanism ensures manufacturing precision without interrupting the overall printing process
2Manufacturing precision
If sensors and correction tools are added to detect and fix errors during printing, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The printing head assembly is designed to perform multiple functions: depositing material layers, scanning completed layers with integrated sensors, and correcting detected errors with integrated correction tools. This multi-functionality reduces the need for separate standalone devices and minimizes overall system complexity while achieving high manufacturing precision
3Manufacturing precision
If error correction by material removal is performed, then manufacturing precision is improved, but loss of substance increases
Solution Approach 1:
The correction tool removes material only from specific localized areas where errors are detected, rather than removing material uniformly across the entire printed object. This localized correction approach minimizes material waste while achieving the required dimensional conformity and manufacturing precision
Data Source
AI summary
Embodiments for 3D printing an object by a processor are described. During a 3D printing process to form a 3D printed object, an at least partially completed 3D printed object formed by the 3D printing process is scanned. An error on the at least partially completed 3D printed object is detected based on the scanning of the at least partially completed 3D printed object. The error on the at least partially completed 3D printed object is corrected. The correcting of the error includes causing at least some material from the partially completed 3D printed object to be removed.