Additive Manufacturing Property Prediction via Segment Scanning
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Solution Overview
Problem
In additive manufacturing, determining the property values of components constructed from multiple layers is challenging due to the complexity of process variables, which affects quality and productivity, and existing methods often require actual component construction to assess properties, leading to potential rejects and inefficiencies.
Innovation Solution
A method and device that allow for the determination of property values of segments of manufacturing products by analyzing process parameter sets and segment scanning direction distributions, enabling virtual segmentation and simulation of macro property values before actual construction, thereby optimizing process variables and reducing rejects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If actual component construction is performed to assess properties, then measurement accuracy is improved, but productivity deteriorates due to time-consuming construction and potential rejects
Solution Approach 1:
The patent performs property value determination in advance through simulation before actual component construction. The method calculates macro property values based on process parameter sets and segment scanning direction distributions, allowing quality assessment to be completed prior to manufacturing, thus avoiding time-consuming construction cycles and potential rejects while maintaining accurate property evaluation
Solution Approach 2:
The patent creates a virtual model of the component by dividing it into segments and simulating the construction process. Instead of building the actual component to measure properties, the method uses a digital twin approach where the virtual segment model undergoes simulated solidification processes, enabling property assessment without physical construction while preserving measurement accuracy through realistic simulation parameters
2Manufacturing precision
If process variables are optimized through actual construction and testing, then manufacturing precision is improved, but loss of substance increases due to material consumption and rejects
Solution Approach 1:
The patent determines property values and assesses component quality before actual construction through simulation. By calculating macro property values from process parameter sets and segment scanning direction distributions in advance, the method identifies optimal process variables without consuming construction material, eliminating rejects and reducing substance loss while maintaining high manufacturing precision
Solution Approach 2:
The simulation system uses the same process parameter sets and construction logic that will be applied to the actual component. The virtual segment model self-evaluates its own properties through the simulated solidification process, allowing the system to optimize material usage and predict quality outcomes without external testing or material consumption
3Manufacturing precision
If detailed analysis of process parameters is performed, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent divides the component into multiple segments, each with uniform process parameter sets. This segmentation allows detailed analysis of process parameters to be performed on manageable individual segments rather than the entire complex component. The macro property value is then determined by combining segment-level analyses, maintaining high manufacturing precision while reducing the complexity burden through modular processing
Solution Approach 2:
The patent applies different process parameter sets to different segments based on their specific requirements. Instead of using a single complex global model, the method tailors the simulation to local segment characteristics, allowing detailed parameter analysis where needed while simplifying other areas. This localized approach maintains high manufacturing precision without requiring uniformly high complexity throughout the entire system
Data Source
AI summary
Disclosed is a method and a device for determining property values of a segment of a manufacturing product made by an additive manufacturing process. In the process, a parameter set is determined which includes a defined group of process parameter values for the construction process of a layer of the segment. At least one process parameter value comprises a layer scanning direction arrangement. Furthermore, a segment scanning direction distribution is determined for the construction process of the segment. A macro property value of the segment is determined based on the parameter set and the segment scanning direction distribution. The invention additionally relates to a method for testing a manufacturing product, to a control data generation device, to a control device for a production device, and to a production device. The invention also relates to a method for setting up a basic property database and to a property database system.