3D Fabrication Shape Correction for Thermal Shrinkage
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Solution Overview
Problem
Conventional 3D fabrication techniques fail to accurately produce desired three-dimensional objects due to unaddressed shrinkage caused by temperature drops after fabrication, despite existing methods for correcting image distortion and suppressing shrinkage.
Innovation Solution
A 3D fabrication apparatus and method that incorporates a sensor to measure the shape of the object during and after fabrication, predicts displacement due to temperature changes, and adjusts the fabrication process using correction vectors to maintain the desired shape, employing both feedback and feed-forward control mechanisms to improve accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional 3D fabrication methods are used without temperature compensation, then the fabrication process is simple, but the manufacturing precision deteriorates due to shrinkage caused by temperature drop
Solution Approach 1:
The system performs preliminary measurement of the fabricated object's shape after fabrication, before the object is removed from the apparatus. This early measurement allows the correction amount calculation unit to compute compensation values while the object is still accessible, enabling pre-correction of shape data for subsequent fabrication steps without adding complex post-processing equipment.
Solution Approach 2:
The measurement result acquisition unit continuously acquires shape data of fabricated objects, and the correction amount calculation unit uses this feedback to calculate correction amounts that are applied to subsequent fabrication. This closed-loop feedback system automatically adjusts for temperature-induced shrinkage by using actual measurement data from previous fabrication cycles to improve the accuracy of next cycle.
2Manufacturing precision
If no shape measurement is performed during fabrication, then the fabrication process is faster, but the manufacturing precision deteriorates due to uncorrected temperature-induced shrinkage
Solution Approach 1:
The fabrication apparatus performs self-measurement of its own fabricated objects using the measurement unit integrated within the apparatus. The object measurement unit measures the shape of the object that the apparatus itself has just fabricated, eliminating the need for external measurement equipment and enabling automatic self-correction of fabrication parameters for subsequent objects.
Solution Approach 2:
The system performs preliminary measurement of the fabricated object's shape after fabrication, before the object is removed from the apparatus. This early measurement allows the correction amount calculation unit to compute compensation values while the object is still accessible, enabling pre-correction of shape data for subsequent fabrication steps without adding complex post-processing equipment.
3Manufacturing precision
If correction amount calculation is not performed, then the fabrication process is simpler, but the manufacturing precision deteriorates due to uncorrected shape deviations
Solution Approach 1:
The measurement result acquisition unit continuously acquires shape data of fabricated objects, and the correction amount calculation unit uses this feedback to calculate correction amounts that are applied to subsequent fabrication. This closed-loop feedback system automatically adjusts for temperature-induced shrinkage by using actual measurement data from previous fabrication cycles to improve the accuracy of next cycle.
Solution Approach 2:
The fabrication apparatus performs self-measurement of its own fabricated objects using the measurement unit integrated within the apparatus. The object measurement unit measures the shape of the object that the apparatus itself has just fabricated, eliminating the need for external measurement equipment and enabling automatic self-correction of fabrication parameters for subsequent objects.
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 enables the precise fabrication of three-dimensional objects by predicting and correcting for shape changes caused by temperature-induced shrinkage, enhancing the accuracy and reliability of the fabrication process.
Implementation Method 1
there is a case in which a desired three-dimensional object cannot be fabricated, and it is necessary to correct a fabrication process... does not consider the influence of shrinkage caused by temperature drop after fabrication
Data Source
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AI summary
An object of the present disclosure is to provide a fabrication apparatus, a controller, and a method to fabricate a desired three-dimensional object. A fabrication apparatus to fabricate a three-dimensional object, the fabrication apparatus includes a fabricated-object-shape measurement unit (340) to measure a planar shape of a fabrication layer, a displaced-shape prediction unit (350) to predict a displacement amount of a shape of the fabrication layer after a predetermined time has elapsed since fabrication of the fabrication layer, and a correction-vector output unit (370) to correct fabrication data of a next fabrication layer to be fabricated next to the fabrication layer based on planar shape data of the fabrication layer measured by the fabricated-object-shape measurement unit (340) and the displacement amount predicted by the displaced-shape prediction unit (350).