3D Printing Geometry Correction From Partial Scan Deviations
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Solution Overview
Problem
Existing 3D printing processes lack effective quality control methods to ensure dimensional accuracy, particularly in areas inaccessible to three-dimensional scanning, leading to complex and disruptive mechanical adjustments to correct deviations from specified dimensions.
Innovation Solution
A method for producing 3D structures that involves capturing the actual geometry of the printed structure, determining initial deviations in scanned areas, and using these data to generate corrected 3D printing data to adjust subsequent layers, thereby compensating for deterministic distortions in unscanned areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If three-dimensional scanning is used to measure the produced 3D structure, then measurement data for deviation determination is obtained, but unscanned areas remain inaccessible leading to incomplete deviation data
Solution Approach 1:
The patent creates a digital copy (point cloud model) of the physical 3D structure through scanning. This digital replica allows for complete analysis and deviation measurement without physical access constraints. The point cloud model serves as a virtual representation that can be processed computationally to determine deviations even in areas that are difficult to physically access.
Solution Approach 2:
The patent introduces an intermediary computational process that uses the scanned point cloud data to infer deviations in unscanned areas. By establishing correspondence between scanned and unscanned regions through geometric relationships and deviation patterns, the system mediates between incomplete measurement data and complete deviation analysis.
2Manufacturing precision
If mechanical adjustments are made to correct deviations from specified dimensions, then dimensional accuracy is improved, but the process becomes complex and disruptive
Solution Approach 1:
The patent replaces mechanical adjustment systems with a computational correction system. Instead of physically adjusting the 3D printing device components, the invention uses software algorithms to analyze deviation data and generate corrected 3D printing data. This substitution eliminates complex mechanical adjustment mechanisms while achieving the same dimensional accuracy improvement.
Solution Approach 2:
The patent implements a feedback loop where deviation measurements from scanned structures are fed back into the 3D printing data generation process. The system continuously monitors actual dimensions, compares them to target dimensions, and automatically adjusts subsequent printing parameters or corrects the digital model to compensate for detected deviations, eliminating the need for manual mechanical adjustments.
3Ease of manufacture
If deviation correction is applied to accessible areas only, then processing is simpler, but unscanned areas remain inaccurate
Solution Approach 1:
The patent creates a universal correction methodology that simultaneously handles both scanned and unscanned areas through a single computational process. The deviation determination system is designed to work across the entire structure by using relationships between scanned reference areas and unscanned target areas, providing comprehensive correction without requiring separate procedures for different regions.
Data Source
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AI summary
The aim of the invention, which relates to a method for producing a 3D structure in a 3D printing method, is that of specifying a solution by means of which an automated correction of the 3D printing data used for the 3D printing method for the 3D structure (30) to be generated is carried out when deviations occur during the manufacturing of the 3D structures (31). This aim is achieved in that: the 3D printing data are data of a target geometry (30) of the 3D structure; the generated 3D structure (31) is three-dimensionally measured after the 3D structure (31) is generated, wherein three-dimensional de facto incomplete data of an actual geometry (31) of the 3D structure are generated which are reproduced in a model (34) that comprises one or more unscanned regions (35); first deviations between points P (37) on a surface of the target geometry of the 3D structure and associated points P' (36) on the surface of the actual geometry (31) of the 3D structure are determined in the scanned regions; further deviations (29) in the unscanned regions (35) of the surface of the generated 3D structure (31) are determined; and corrected 3D printing data (38) are generated by means of these determined first and further deviations (28, 29).