Additive Manufacturing Region Compensation for Dimensional Accuracy
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Solution Overview
Problem
Existing additive manufacturing methods face challenges in achieving accurate and reproducible results due to spatially dependent deformations caused by inhomogeneous temperature distributions and manufacturing region-specific variations, leading to inconsistencies in workpiece dimensions and geometry.
Innovation Solution
A method and apparatus that utilize a second data set representing spatially dependent deformations to correct and compensate for individual manufacturing region-specific deformations by adjusting the movement and process parameters of the structuring tool, using a first data set to define workpiece layers and a second data set to account for spatially dependent deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If selective laser sintering or melting is used to manufacture workpieces layer by layer, then workpieces can be produced with complex geometries, but spatially dependent deformations occur due to inhomogeneous temperature distributions causing dimensional inaccuracies
Solution Approach 1:
The patent applies preliminary action by determining correction values before the actual workpiece manufacturing process. Test objects are manufactured in different manufacturing regions, measured, and used to calculate correction values that are stored and applied to subsequent workpieces. This pre-characterization of the manufacturing platform eliminates dimensional inaccuracies caused by inhomogeneous temperature distributions without requiring changes to the manufacturing process itself.
Solution Approach 2:
The patent implements feedback by measuring the actual dimensions of test objects manufactured in different regions of the manufacturing platform, comparing them to target dimensions, and using these measurements to determine correction values. These correction values are then applied to adjust manufacturing parameters for subsequent workpieces, creating a closed-loop system that compensates for spatially dependent deformations.
2Volume of moving object
If the manufacturing platform size is increased to support larger workpieces, then larger workpieces can be manufactured, but spatially dependent deformations vary across different regions of the platform
Solution Approach 1:
The patent applies segmentation by dividing the manufacturing platform into multiple discrete manufacturing regions and determining separate correction values for each region. Test objects are manufactured in different regions (e.g., center, corners, edges) and each region is characterized independently. This allows the system to account for regional variations in temperature distribution and deformation patterns across the entire platform, enabling accurate manufacturing of large workpieces that span multiple regions.
3Manufacturing precision
If measurement and correction processes are implemented to improve accuracy, then dimensional precision improves, but measurement and data processing time increase
Solution Approach 1:
The patent minimizes time loss by performing measurements and determining correction values in advance, before actual production begins. The correction values are stored in memory and automatically applied during manufacturing without requiring real-time measurement or intervention. This approach shifts the time investment to a one-time setup phase rather than continuously during production, making the correction process efficient and scalable.
4Manufacturing precision
If temperature control is improved to reduce deformations, then manufacturing precision improves, but energy consumption and system complexity increase
Solution Approach 1:
The patent uses feedback from measurements of test objects to determine correction values that compensate for temperature-induced deformations. Rather than attempting to control temperature uniformly across the entire platform through complex heating/cooling systems, the method measures actual deformations and uses this information to adjust manufacturing parameters (such as laser power, scanning speed, or layer thickness) to compensate for regional temperature variations. This approach achieves improved precision without requiring complex active temperature control.
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
Improves the size accuracy and reproducibility of additively manufactured workpieces by addressing spatially dependent deformations, enabling cost-effective implementation on existing apparatuses with minimal hardware modifications.
Implementation Method 1
Selected powder particles in the powder bed are partially and/or completely melted with the aid of one or more laser beams or electron beams
Implementation Method 2
Selected powder particles in the powder bed are partially and/or completely melted with the aid of one or more laser beams or electron beams
Implementation Method 3
In what is known as binder jetting, a powdery starting material is adhesively bonded at selected points using a liquid binder
Data Source
AI summary
A method for additively manufacturing a workpiece having lateral workpiece dimensions includes obtaining a first data set defining the workpiece in layers arranged on top of the other. The method includes providing a manufacturing platform having lateral platform dimensions that are greater than the lateral workpiece dimensions. The method includes providing a structuring tool movable relative to the manufacturing platform. The method includes selecting an individual manufacturing region on the manufacturing platform. The method includes obtaining a second data set that represents individual layer deformations that are dependent on the selected manufacturing region. The method includes producing a defined material layer of the workpiece in the manufacturing region by controlling the structuring tool using the first and second data sets. The method includes repeating the producing in order to produce further defined material layers one on top of the other using the first data set and the second data set.