Additive Manufacturing Slice Position Adjustment for Warping
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Solution Overview
Problem
Additive manufacturing processes, such as selective laser melting, often result in workpiece distortion due to thermal stresses, which requires post-processing to relieve, increasing complexity and cost.
Innovation Solution
A method to adjust the positions of workpiece slices during the additive manufacturing process based on expected warping, using a test workpiece to determine and measure distortions, and shifting slice positions to counteract warping, thereby reducing the need for post-processing and supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If supports are used during the build and post-treatment is applied to relieve thermal stresses, then workpiece distortion is reduced, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-adjusting the positions of workpiece slices before manufacturing to compensate for expected thermal warping. The system determines adjusted positions of workpiece slices based on predicted thermal stresses, so that when warping occurs during additive manufacturing, the workpiece naturally returns to the desired geometry, eliminating the need for post-treatment stress relief processes.
Solution Approach 2:
The patent converts the harmful effect of thermal warping into a beneficial outcome by intentionally positioning slices to account for expected distortion. The system uses predicted warping patterns to adjust slice positions in advance, so that the thermal stresses that would normally cause defects actually help the workpiece achieve the target geometry without requiring additional support structures or post-processing.
2Stability of the object's composition
If supports are used during the build, then workpiece stability is improved, but the number of supports and post-processing requirements increase
Solution Approach 1:
The system performs preliminary calculation of thermal warping effects and adjusts slice positions beforehand to compensate for expected distortion. This pre-adjustment eliminates the need for extensive support structures during building, as the workpiece geometry is already compensated for thermal stresses, reducing both support requirements and subsequent post-processing needs.
3Productivity
If slice positions are adjusted to counteract warping, then post-processing requirements are reduced, but computational complexity increases
Solution Approach 1:
The patent implements feedback by using measured warping data from test workpieces to refine and update the warping prediction model. The system builds test workpieces, measures their actual warping using coordinate measuring machines or other measurement devices, and uses this empirical data to improve the accuracy of thermal stress predictions for subsequent production workpieces, creating a continuous improvement loop that reduces computational complexity over time.
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 approach minimizes post-processing requirements and support usage by proactively adjusting slice positions to maintain the intended surface geometry, reducing manufacturing complexity and cost.
Implementation Method 1
a laser beam is scanned across portions of the powder layer that correspond to a cross-section (slice) of the workpiece being constructed. The laser beam melts or sinters the powder to form a solidified layer.
Implementation Method 2
The laser beam melts or sinters the powder to form a solidified layer.
Implementation Method 3
A workpiece can distort, during or after the additive build, due to resulting thermal stresses.
Data Source
AI summary
A method builds a workpiece using an additive manufacturing process, wherein the workpiece is built up by consolidating material in a layer-by-layer manner. The method includes receiving an initial geometric model defining surface geometry of the workpiece, determining workpiece slices to be consolidated as layers of the workpiece during the additive manufacturing process from the initial geometric model, determining adjusted positions of the workpiece slices adjusted from initial positions of the workpiece slices as determined from the initial geometric model, the determination of the adjusted positions based upon warping of the workpiece expected to occur during or after the additive manufacturing process, and building the workpiece using the additive manufacturing process, wherein the workpiece slices are formed in the adjusted positions.