Additive Manufacturing Calibration via Patch Analysis

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Solution Overview

Problem

Additive manufacturing systems face quality issues due to non-optimal interaction between printing agents and reused or mixed build material powders, leading to suboptimal maximum contone levels and resulting defects in 3D objects.

Innovation Solution

An additive manufacturing system calibration process involving a print parameter determination module that forms patches with varying printing liquid densities, uses sensors to analyze the interaction between printing liquid and powder, and sets optimal print parameters for subsequent operations based on the analysis.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If printing liquid is applied to reused or mixed build material powders, then the manufacturing process can continue, but the interaction between printing liquid and powder becomes non-optimal leading to suboptimal maximum contone levels

Engineering Contradiction:

Improvemanufacturing process continuityVSAvoidmaximum contone level

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system performs a calibration process before actual printing operations to determine optimal print parameters. Patches are formed with varying printing liquid densities to pre-characterize the interaction between printing liquid and the specific powder batch, allowing the maximum contone level to be determined in advance for subsequent printing operations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Sensors detect the interaction characteristics between printing liquid and powder by analyzing the formed patches. This feedback information is used to determine the optimal maximum contone level and number of printing passes, creating a closed-loop system that adapts to the specific powder characteristics

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If printing liquid is applied at high density to improve layer quality, then manufacturing precision improves, but printing liquid pooling occurs

Engineering Contradiction:

Improveprinting liquid distribution uniformityVSAvoidprinting liquid pooling

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The system determines the optimal maximum contone level as a specific parameter value based on sensor analysis of patch formation. By changing the printing liquid density parameter to match the optimal value, the system achieves uniform distribution without pooling

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system applies printing liquid at controlled, optimal densities rather than excessive amounts. The calibration process identifies the precise amount needed for optimal interaction, avoiding both under-application and over-application that would cause pooling

Inventive Principle:

Principle #16Partial or excessive action

3Manufacturing precision

If the number of printing passes is increased to ensure complete liquid absorption, then manufacturing precision improves, but production time increases

Engineering Contradiction:

Improveprinting liquid absorption completenessVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system determines the optimal number of printing passes as a specific parameter based on sensor analysis. By changing this parameter to the optimal value, the system achieves complete liquid absorption in the minimum necessary passes, avoiding unnecessary time consumption

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Sensors provide feedback on liquid absorption characteristics from the patch formation process. This information is used to determine the optimal number of passes required for complete absorption, creating a data-driven approach that eliminates trial-and-error and minimizes production time

Inventive Principle:

Principle #23Feedback

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 process ensures optimal printing liquid distribution, preventing pooling and enhancing the mechanical properties of 3D objects by determining the maximum contone level and number of printing passes, thereby improving part quality.

Implementation Method 1

Additive manufacturing systems such as three-dimensional printing systems typically generate three-dimensional (3D) objects through selective solidification of a build material on a layer-by-layer basis according to a digital 3D object model

Methodology Applied

Scientific EffectSelective solidification:

Implementation Method 2

the printing liquid infiltrates into a powder layer to form bound material particles

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentUS20240359408A1Additive manufacturing systems

Publication Date: 2024.10.31 PERIDOT PRINT LLC

AI summary

According to an example, a method for setting print parameters for a subsequent printing operation may comprise forming a layer of powder, printing a plurality of patches on the formed layer, obtaining sensor data corresponding to at least two patches of the plurality of patches, determining for each of the at least two of the plurality of patches characteristics of the interaction between the printing liquid and powder in the formed layer based on the obtained sensor data, and setting the print parameters based on the determined characteristics of the interaction.