3D Model Adjustment for Additive Manufacturing Tolerances
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Solution Overview
Problem
Additive manufacturing processes often result in objects that undergo post-processing operations, leading to changes in size, shape, or dimensions, which can make the objects unsuitable for their intended purposes due to deviations from required tolerances.
Innovation Solution
A method is introduced to adjust the three-dimensional representation of objects before manufacturing, using adjustment parameters to account for expected changes during post-processing operations, such as coating or surface modifications, to ensure the final object meets the required specifications by applying transformations or modifications to the digital model.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If post-processing operations are applied to manufactured objects, then surface quality or functional properties are improved, but the size, shape, or dimensions of the objects change beyond acceptable tolerances
Solution Approach 1:
The patent applies preliminary action by modifying the digital 3D model before manufacturing to anticipate and compensate for post-processing changes. The system calculates expected dimensional changes from post-processing operations and adjusts the model dimensions in advance, so that after post-processing, the object achieves both improved surface quality and maintains required dimensional tolerances.
Solution Approach 2:
The patent implements preliminary anti-action by applying counteracting modifications to the digital model that oppose the expected post-processing changes. If post-processing is expected to increase dimensions, the model is deliberately made smaller; if post-processing will remove material, the model is made larger, thereby compensating for the adverse dimensional effects and achieving both surface quality improvement and dimensional accuracy.
2Manufacturing precision
If the digital model is modified to compensate for post-processing changes, then final object dimensional accuracy is improved, but additional processing steps and computational complexity are introduced
Solution Approach 1:
The patent applies self-service by implementing an automated system that performs the compensation calculations and model modifications without requiring manual intervention. The software automatically calculates expected post-processing dimensional changes, determines appropriate compensation values, and applies the necessary transformations to the digital model, thereby achieving high dimensional accuracy while minimizing the complexity burden on operators.
Solution Approach 2:
The patent utilizes parameter changes by systematically varying model dimensions based on calculated compensation values. The system modifies specific geometric parameters of the digital model (such as length, width, height, or radius) by precise amounts that counterbalance expected post-processing changes, thereby achieving dimensional accuracy through controlled parameter adjustments rather than complex manual procedures.
3Manufacturing precision
If compensation values are calculated based on post-processing operations, then final object tolerances are maintained, but additional computational time and processing steps are required
Solution Approach 1:
The patent applies preliminary action by performing compensation calculations and model modifications during the digital design and preparation phase, before physical manufacturing begins. This advance planning ensures that tolerance compliance is built into the model itself, and the computational work is completed once during model preparation rather than requiring iterative adjustments during or after manufacturing, thereby maintaining precision while optimizing time efficiency.
Data Source
AI summary
A method of adjusting a three-dimensional representation of an object to be manufactured in an additive manufacturing process comprises determining a processing operation to be applied to the object, and adjusting the three-dimensional representation of the object based on adjustment parameters associated with the processing operation.