3D Printing Real-Time Defect Correction via Sensor Feedback
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Solution Overview
Problem
Existing 3D printing technologies face defects during the construction process due to material fall, print head disruptions, and other errors, which can escalate small issues into significant problems, leading to waste and unusable objects.
Innovation Solution
A 3D construction system that uses an online 3D blueprint model, a 3D print head, and at least one 3D perception sensor to generate sensor readings, create an online 3D replica model, and compare it to the blueprint to identify differences, modifying the control plan in real-time to correct defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If 3D printing is performed without real-time monitoring, then the printing process can proceed quickly, but defects may occur and expand leading to waste and unusable objects
Solution Approach 1:
The system continuously scans the constructed portion of the object using 3D perception sensors and compares the scanned data against the 3D blueprint model in real-time. When deviations are detected, the control plan is automatically modified to correct the defects, ensuring high object quality while maintaining printing speed through automated closed-loop control.
Solution Approach 2:
The system performs preliminary defect detection by scanning the constructed portion before defects can expand into large problems. By identifying and correcting small deviations early in the printing process, the system prevents waste and ensures object quality without requiring complete reprints.
2Reliability
If 3D perception sensors and real-time monitoring are added, then defect detection and correction are enabled, but the system complexity increases
Solution Approach 1:
The 3D perception sensors serve multiple functions: they scan the constructed portion, generate sensor readings, enable defect detection, and provide data for control plan modification. This multi-functionality reduces the need for separate monitoring and control systems, thereby managing system complexity while improving object quality.
Solution Approach 2:
The system merges the scanning function, defect detection function, and control plan modification function into an integrated real-time monitoring system. By combining these functions that work together in sequence, the overall system complexity is managed more effectively than if separate independent systems were used.
3Measurement precision
If continuous scanning and real-time comparison are performed, then defect detection accuracy is improved, but the processing time and computational load increase
Solution Approach 1:
The system performs scanning and comparison operations at strategically chosen intervals during the printing process rather than continuously at every single step. This partial action approach maintains high defect detection accuracy for critical portions while reducing overall processing time and computational load compared to exhaustive continuous monitoring.
Data Source
AI summary
A 3D construction system for creating an object includes, among other components, an online 3D blueprint model for the object and a 3D print head. An online control plan for controlling operation of the 3D print head to create the object according to the online 3D blueprint model is also provided. At least one 3D perception sensor scans a constructed portion of the object to generate sensor readings. A processing device, which is part of a computer system, creates an online 3D replica model of the constructed portion of the object using the sensor readings, and compares the online 3D replica model to the online 3D blueprint model or an ideal printed 3D model to identify a difference. The online control plan is modified responsive to the difference.