Dimensional Compensation for Additive Manufacturing Accuracy

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Solution Overview

Problem

Additive manufacturing techniques face challenges in achieving dimensional accuracy due to material expansion or shrinkage during the solidification process, leading to deviations from intended object dimensions.

Innovation Solution

A method involving dimensional compensation using a mapping resource that applies scaling and offset factors to object model data, based on the intended object placement within the fabrication chamber, to adjust for anticipated dimensional changes, thereby improving accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If additive manufacturing is used to generate three-dimensional objects through solidification, then manufacturing complexity is reduced and new capabilities are enabled, but dimensional accuracy deteriorates due to material expansion or shrinkage during solidification

Engineering Contradiction:

Improvemanufacturing capabilityVSAvoiddimensional accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by calculating and applying dimensional compensation values to the 3D model data before the additive manufacturing process begins. The system determines compensation values based on the object's geometry, material properties, and build parameters, then modifies the model dimensions in advance to counteract anticipated thermal expansion or shrinkage during solidification. This pre-compensation approach resolves the contradiction by enabling accurate dimensional control without changing the manufacturing process itself.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent employs parameter changes by dynamically adjusting the dimensional parameters of the 3D model based on calculated compensation values. The system modifies length, width, height, and other dimensional parameters of the digital model to compensate for expected material expansion or shrinkage. This allows the final manufactured object to achieve the intended dimensional accuracy despite the inherent thermal effects during additive manufacturing solidification.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If dimensional compensation is applied to object model data, then manufacturing precision is improved, but device complexity increases due to additional processing steps

Engineering Contradiction:

Improvedimensional accuracyVSAvoidprocessing complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system applies self-service by automatically calculating dimensional compensation values based on the object's geometric parameters, material properties, and build conditions. The compensation calculation is performed autonomously within the existing software framework, and the modified model data is directly used in the manufacturing process. This eliminates the need for separate manual compensation procedures or additional hardware devices, resolving the contradiction by improving dimensional accuracy through integrated software-based processing.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent demonstrates universality by implementing a compensation mechanism that works across different object geometries, materials, and build parameters within a single integrated system. The same software module calculates and applies dimensional compensation for various additive manufacturing scenarios, eliminating the need for separate compensation systems for different cases. This multi-functional approach improves dimensional accuracy without proportionally increasing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 effectively compensates for material expansion or shrinkage, ensuring generated objects are closer to their intended size by applying interpolated dimensional corrections, enhancing overall dimensional accuracy.

Implementation Method 1

the solidification method may include heating the layers of build material to cause melting in selected regions

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

Additive manufacturing techniques may generate a three-dimensional object through the solidification of a build material

Methodology Applied

Scientific EffectSolidification: Freezing

Implementation Method 3

material expansion or shrinkage during the solidification process

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 4

material expansion or shrinkage during the solidification process

Methodology Applied

Scientific EffectThermal contraction: Thermal Contraction

Data Source

PatentUS11597155B2Dimensional compensations for additive manufacturing

Publication Date: 2023.03.07 PERIDOT PRINT LLC

AI summary

In an example, a method includes receiving, at least one processor, object model data representing at least a portion of an object that is to be generated by an additive manufacturing apparatus by fusing build material within a fabrication chamber. An intended object placement location within the fabrication chamber may be determined, and a dimensional compensation to apply to the object model data may be determined using a mapping resource relating dimensional compensations to object placement locations. The determined dimensional compensation may be applied to the object model data to generate modified object model data using at least one processor.