Overheating Prediction in Additive Manufacturing via Simulation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

In additive manufacturing, predicting and preventing local overheating during the build process is challenging, leading to visual defects, structural issues, and wastage of time and materials.

Innovation Solution

A computer-implemented method using finite element modeling to simulate the build process, determining temperature over time at multiple locations, calculating maximum temperature, thermal gradient, and heat modulus, and computing an overheating index to predict likely overheating locations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If additive manufacturing is performed without overheating prediction, then manufacturing process can proceed quickly, but local overheating occurs causing defects and material waste

Engineering Contradiction:

Improvebuild qualityVSAvoiddesign iteration time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent performs finite element analysis simulation before actual additive manufacturing to predict temperature distribution and identify potential overheating locations. This preliminary action allows designers to modify the model beforehand, preventing defects and avoiding repeated manufacturing iterations, thus improving build quality while reducing time loss.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If finite element analysis simulation is performed to predict overheating, then overheating locations can be identified and prevented, but computational complexity and analysis time increase

Engineering Contradiction:

Improvetemperature control accuracyVSAvoidsimulation system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces physical trial-and-error manufacturing with computational finite element analysis simulation. By using numerical methods to predict temperature distribution and overheating locations before manufacturing, the system achieves precise temperature control without the complexity of physical experimentation and iteration.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If multiple temperature parameters are calculated at each location, then overheating prediction accuracy improves, but computational load increases

Engineering Contradiction:

Improvetemperature measurement accuracyVSAvoidcomputational energy consumption

Core Design Contradiction:

Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The patent calculates multiple temperature parameters (maximum temperature, thermal gradient, heat modulus) specifically at locations identified as potential overheating zones rather than uniformly across the entire model. This localized approach maintains measurement precision for critical areas while reducing overall computational energy consumption.

Inventive Principle:

Principle #3Local quality

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 method effectively predicts overheating locations before actual manufacturing, reducing the likelihood of defects and material waste, and allows for automated redesign or parameter adjustments to prevent overheating.

Implementation Method 1

simulating build of the object using the finite element model including determining a temperature over time at a plurality of locations of the object

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

extracting, for each of the plurality of locations, a thermal gradient

Methodology Applied

Scientific EffectThermal gradient: Temperature Gradient

Implementation Method 3

determining, for each of the plurality of locations, a maximum temperature based on the corresponding temperature over time

Methodology Applied

Scientific EffectTemperature measurement:

Implementation Method 4

calculating, for each of the plurality of locations, a heat modulus

Methodology Applied

Scientific EffectHeat modulus:

Data Source

PatentUS12299362B2System and methods for predicting overheating for additive manufacturing using simulation

Publication Date: 2025.05.13 MATERIALISE NV

AI summary

Systems and methods for predicting locations of overheating of one or more objects for build of the one or more objects by additive manufacturing using simulation. A method includes simulating temperature of an object as a function of spatial location during a layer by layer build using powder based additive manufacturing comprising determining a temperature over time at a plurality of locations of a plurality of layers of the object. The method further includes calculating, for each of the plurality of locations, an overheating index that is a function of each of a corresponding maximum temperature, thermal gradient, and heat modulus. The method further includes, based on one or more overheating indexes of one or more locations exceeding the threshold indicating overheating, adjusting a build of the object.