Additive Manufacturing Dimensional Compensation Inference Model
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Solution Overview
Problem
Additive manufacturing techniques face challenges in achieving dimensional accuracy due to thermal processes and material behavior, leading to inconsistencies in object size and shape during the solidification of build materials.
Innovation Solution
A method is developed to generate an inference model using a training dataset that accounts for dimensional inaccuracies by analyzing object placement, volume, and solid proportion, allowing for the application of scaling and offset factors to compensate for these inaccuracies, thereby improving the accuracy of object generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If additive manufacturing uses thermal solidification processes to generate three-dimensional objects layer by layer, then objects can be manufactured with complex geometries and customized designs, but dimensional inaccuracies occur due to thermal expansion and contraction during solidification
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing compensation values in a lookup table before manufacturing. The system determines dimensional compensation values based on object volume and solid proportion characteristics, then uses these pre-computed values to adjust the manufacturing process, eliminating the need for real-time complex calculations during production.
Solution Approach 2:
The patent changes physical parameters by adjusting object model dimensions based on compensation values. The system modifies the digital model parameters (scaling factors) before manufacturing based on the object's volume and solid proportion, thereby compensating for anticipated thermal expansion and contraction effects during the additive manufacturing process.
2Ease of manufacture
If the build material is heated to cause melting and solidification in selected regions, then selective solidification can be achieved to form three-dimensional objects, but thermal processes cause dimensional deviations from the intended object model
Solution Approach 1:
The patent implements feedback by using measured dimensional data from previously manufactured objects to refine compensation values. The system collects data on actual dimensional deviations, updates the lookup table with improved compensation values based on object volume and solid proportion, and applies these refined values to subsequent manufacturing operations.
Solution Approach 2:
The system performs preliminary compensation by adjusting the object model dimensions before manufacturing based on pre-calculated compensation values. This preliminary adjustment accounts for anticipated thermal effects, allowing the selective solidification process to produce more accurate dimensions without modifying the thermal process itself.
3Manufacturing precision
If compensation values are determined based on object volume and solid proportion, then dimensional accuracy can be improved, but additional measurements and calculations are required
Solution Approach 1:
The patent uses copying by creating a digital lookup table that stores compensation values corresponding to different object volume and solid proportion characteristics. Instead of performing complex real-time calculations, the system copies the appropriate pre-calculated compensation value from the lookup table based on the object's characteristics, significantly reducing computational complexity.
Solution Approach 2:
The system performs preliminary calculations by pre-computing compensation values for various object characteristics and storing them in advance. This eliminates the need for complex real-time calculations during manufacturing, as the system only needs to query the pre-computed lookup table using the object's volume and solid proportion as keys.
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 method significantly enhances the dimensional accuracy of objects produced by additive manufacturing, reducing errors and ensuring objects are closer to their intended size by compensating for thermal expansion and contraction.
Implementation Method 1
the solidification method may include heating the layers of build material to cause melting in selected regions
Implementation Method 2
compensating for thermal expansion and contraction
Implementation Method 3
compensating for thermal expansion and contraction
Data Source
AI summary
In an example, a method includes generating a training dataset for an inference model to generate dimensional modifications to apply to object models to compensate for departures from model dimensions in objects generated using additive manufacturing based on those object models. Generating the training dataset may include acquiring, for each of a plurality of generated objects, (i) an indication of a first dimensional inaccuracy and a second dimensional inaccuracy, wherein the first and second dimensional inaccuracies are acquired in a direction of a first axis and relate to respective first and second object dimensions; and (ii) an indication of object placement within a fabrication chamber during object generation.