3D Printing Vector Endpoint Correction for Scan Speed Errors
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Solution Overview
Problem
Three-dimensional (3D) printing systems face challenges with scan speed and execution time errors during the layer-by-layer fabrication of 3D articles, leading to inconsistencies and potential overheating or overcuring issues due to inaccuracies in converting virtual 3D body slices into energy beam control vectors.
Innovation Solution
A controller system is implemented to process virtual 3D bodies into vector slices, analyzing and correcting scan speed errors by adjusting endpoints of vectors when errors exceed a predetermined threshold, ensuring accurate and efficient energy beam scanning, thereby maximizing fabrication speed and reducing overheating risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If virtual 3D body slices are converted to vector form for energy beam control, then the 3D printing process can be executed, but scan speed and execution time errors occur leading to inconsistencies and overheating issues
Solution Approach 1:
The system performs preliminary analysis and correction of scan speed errors during the vector slice generation phase, before actual printing execution. The controller pre-calculates optimal vector paths that account for expected speed variations, and adjusts endpoints in advance to compensate for anticipated timing deviations, thereby preventing consistency issues before they occur during high-speed fabrication
Solution Approach 2:
The system implements a feedback mechanism where the controller continuously monitors actual scan speed deviations from planned trajectories and dynamically adjusts subsequent vector paths. By analyzing timing data from executed vectors and comparing it against expected values, the system real-time corrects endpoint positions to maintain consistent scan speeds, preventing overheating and ensuring reliability during rapid fabrication
2Productivity
If scan speed is increased to maximize fabrication speed, then productivity improves, but scan speed errors cause overheating or overcuring issues
Solution Approach 1:
The system applies preliminary anti-action by pre-correcting vector endpoints to counteract expected scan speed deviations before they cause harmful effects. The controller calculates anticipated timing errors and adjusts vector paths in advance to compensate, preventing the energy beam from moving too slowly and causing overheating, while maintaining high overall fabrication speeds through optimized pre-correction algorithms
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
The solution enhances the consistency and speed of 3D printing by correcting scan speed errors, resulting in improved repeatability and reduced overheating or overcuring, thereby optimizing the layer-by-layer fabrication process.
Implementation Method 1
Each layer of material is selectively hardened with an energy beam which can be a laser beam, an electron beam, or a particle beam
Implementation Method 2
For the individual slices, analyzing a scan speed error for one or more of the plurality of vectors
Data Source
AI summary
A three-dimensional (3D) printing system includes a print engine and a controller. The print engine includes a motorized build platform, a coating apparatus, and a beam forming unit. The controller is configured to perform the following steps: (a) receiving a virtual 3D body, (b) processing the 3D body to define a plurality of N slices, the N slices individually representing intersections of the 3D body with the slice, (c) processing the N slices to represent solid portions of the 3D body with vectors, the vectors defining contours and hatching patterns, the vectors individually bounded by two endpoints, (d) for the individual slices, analyzing a scan speed error for one or more of the plurality of vectors, and (e) for the individual slices, moving some of the endpoints when the scan speed error exceeds a predetermined threshold to provide a speed corrected slice.