3D Printing Quality Assessment via Testing Pattern Imaging
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Solution Overview
Problem
3D printing processes face variability in material properties and quality due to hardware and process inconsistencies, leading to defects in printed parts, which are difficult to detect using existing testing methods like FLIR cameras or mechanical testers that often damage the parts and require specialized equipment.
Innovation Solution
A 3D printer system that includes a controller and image capture device to analyze a testing pattern deposited onto the build material layer, determining the quality level by assessing the condition of the pattern based on image quality and readability, allowing for non-destructive and cost-effective quality assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical testing equipment is used to test printed parts, then material properties can be determined, but the parts are damaged or destroyed during testing
Solution Approach 1:
The patent uses a testing pattern (copy) deposited on the build material layer to represent quality information, rather than testing the actual printed part. The pattern captures printing process variations and material properties, allowing quality assessment without damaging the final part.
Solution Approach 2:
The testing pattern acts as an intermediary between the printing process and quality assessment. It is deposited on the build material layer and subjected to the same printing conditions, serving as a proxy that reflects printing quality without requiring direct testing of the valuable final part.
2Measurement precision
If FLIR cameras are used to sense heat distribution, then quality information can be obtained, but the equipment is expensive and requires specialized software
Solution Approach 1:
The patent replaces expensive FLIR cameras with a simple, inexpensive imaging device (such as a standard camera or sensor). The testing pattern is a simple deposited material pattern that can be captured by basic imaging equipment, eliminating the need for specialized thermal imaging systems and software.
Solution Approach 2:
The patent substitutes complex thermal sensing systems with a simpler optical imaging system. Instead of measuring heat distribution with expensive FLIR cameras, the system uses visible or near-visible imaging to capture the testing pattern, replacing complex thermal measurement with simpler optical detection.
3Measurement precision
If existing testing methods are used, then quality assessment can be performed, but the process is time-consuming and requires expert execution
Solution Approach 1:
The testing pattern is automatically captured and analyzed by the printing system itself, without requiring external experts or manual testing procedures. The imaging device captures the pattern during or after printing, and automated image processing algorithms analyze the pattern to determine quality metrics, making the system self-testing.
Solution Approach 2:
The system provides real-time feedback by capturing the testing pattern and analyzing it to determine quality levels. This feedback loop allows immediate identification of printing quality issues without waiting for post-processing or expert analysis, enabling rapid quality assessment and process adjustment.
4Measurement precision
If mechanical testing equipment is used, then material properties can be measured, but the equipment is expensive and requires expert operation
Solution Approach 1:
The patent replaces expensive mechanical testing equipment with inexpensive imaging devices and simple testing patterns. The testing pattern is a basic material deposition that can be captured by standard cameras or sensors, eliminating the need for costly tensile testers, hardness testers, or other specialized mechanical testing equipment.
Solution Approach 2:
The patent substitutes mechanical testing systems with optical imaging systems. Instead of using mechanical equipment to physically test material properties, the system uses light-based imaging to capture the testing pattern, replacing complex mechanical measurement with simpler optical detection and image analysis.
Data Source
Figure 1A
Figure 1B
Figure 1C~2B
AI summary
According to an example, an apparatus may include an image capture device, a controller, and a computer readable storage medium. The computer readable storage medium may include instructions that may cause the controller to receive, from the image capture device, an image of a testing agent deposited in a testing pattern onto a layer of build materials, in which the layer of build materials is to form a section of a three-dimensional printed part. The instructions may also cause the controller to determine a condition of the deposited testing pattern in the received image, wherein the determined condition is to be used to determine a quality level of the layer of build materials based upon the determined condition.