Additive Manufacturing Process Control Using Build-to-Build Feedback
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Solution Overview
Problem
Current additive manufacturing processes rely on iterative, human-in-the-loop methods for process parameter adjustment, which are prone to errors and are time-consuming, as they use after-the-fact data collection to address non-conformances and build problems in powder bed machines.
Innovation Solution
An integrated process control method utilizing software to analyze multiple data sources and leverage learning from previous builds to optimize subsequent processes automatically, by comparing the condition of finished workpieces to predetermined standards and adjusting parameters accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated process control is implemented, then productivity and efficiency are improved, but device complexity increases
Solution Approach 1:
The system implements automated feedback control by sensing workpiece conditions, comparing them to predetermined standards, and automatically adjusting process parameters. This closed-loop feedback mechanism enables the system to self-correct and optimize builds without human intervention, improving productivity while managing complexity through systematic automation.
Solution Approach 2:
The control system performs self-service by automatically analyzing build data, identifying non-conformances, and adjusting process parameters without requiring human operators. The system leverages learning from previous builds to autonomously optimize subsequent builds, reducing labor requirements and improving efficiency.
2Manufacturing precision
If iterative human-in-the-loop methods are used, then manufacturing precision can be maintained, but loss of time and labor increases
Solution Approach 1:
The system performs preliminary actions by establishing predetermined standards and automated adjustment protocols before builds begin. Process parameters are pre-configured and the system is prepared to automatically respond to deviations, eliminating the need for time-consuming manual iteration while maintaining precision through pre-planned control strategies.
Solution Approach 2:
The patent replaces manual human decision-making and adjustment processes with automated electronic control systems. Sensors, processors, and actuators substitute for human operators in detecting workpiece conditions and adjusting parameters, maintaining manufacturing precision while dramatically reducing the time and labor associated with iterative adjustments.
3Adaptability or versatility
If manual parameter adjustment is performed, then adaptability to build problems is improved, but reliability decreases due to human error
Solution Approach 1:
The automated feedback control system continuously monitors build conditions and automatically adjusts parameters in response to detected deviations. This systematic feedback mechanism provides consistent, repeatable responses to build problems without human error, improving reliability while maintaining adaptability through real-time parameter adjustment based on actual build conditions.
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
This approach enables automated, efficient, and error-reduced optimization of additive manufacturing processes, improving workpiece quality and reducing the time and labor required for parameter adjustments.
Implementation Method 1
one or more energy beams are used to selectively fuse a powder contained in an additive manufacturing machine
Implementation Method 2
direct metal laser melting (DMLM)
Implementation Method 3
The shielding gas is used to transfer heat away from the surface of the powder bed
Implementation Method 4
the interaction of the energy beam with the powder generates an emissions plume which can cause detrimental effects
Data Source
AI summary
A method is provided for controlling an additive manufacturing process in which one or more energy beams are used to selectively fuse a powder contained in an additive manufacturing machine having a gas flow therein in order to form a workpiece, in the presence of one or more plumes generated by interaction of the one or more energy beams with the powder, wherein the process is controlled by an electronic controller. The method includes: performing a build process to form a workpiece using a set of initial process parameters; sensing a condition of the finished workpiece; using the electronic controller, comparing the condition of the finished workpiece to a predetermined standard; using the electronic controller, changing one or more of the initial process parameters to define a set of revised process parameters; and performing a subsequent build process using the revised process parameters.