Additive Manufacturing Defect Repair via Layer Scanning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Additive manufacturing processes often result in defective parts due to material shortages, leading to scrapage and wasted time and expensive materials, as existing methods do not effectively monitor and repair defects in real-time during the manufacturing process.
Innovation Solution
A method for repairing parts additively manufactured layer by layer, involving the detection and repair of material defects by adding material during the process, using a scanning tool to identify and geolocate defects and a secondary nozzle to fill in missing material, allowing for continuous monitoring and correction as each layer is formed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additive manufacturing is performed without real-time defect detection and repair, then the manufacturing process is simpler and faster, but the part quality deteriorates and scrapage increases
Solution Approach 1:
The patent implements preliminary action by performing defect detection and repair during the additive manufacturing process itself, before the part is completed. The system scans each layer as it is deposited and immediately repairs detected defects, preventing them from propagating to the final product. This eliminates the need for post-manufacturing inspection and rework, resolving the contradiction between quality and process complexity.
Solution Approach 2:
The patent applies feedback by creating a closed-loop system where the output of each layer (the deposited material) is immediately scanned and analyzed for defects. The scan results feed back to the deposition system, which automatically adjusts and repairs defects in real-time. This continuous feedback mechanism ensures high part quality without requiring complex manual intervention processes.
2Loss of substance
If real-time defect detection and repair is implemented during additive manufacturing, then material waste and time loss are reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The feedback mechanism continuously monitors deposited layers and automatically triggers repair operations when defects are detected. This prevents material waste by immediately correcting deposition errors before they accumulate, eliminating the need to scrap entire parts. The automated feedback loop manages the increased process complexity by handling repairs programmatically rather than requiring manual intervention.
Solution Approach 2:
The system implements self-service by enabling the additive manufacturing process to detect and repair its own defects autonomously. The scan head identifies material deficiencies, and the control system automatically adjusts deposition parameters or activates repair nozzles to correct the issues. This self-correcting capability reduces material waste while managing process complexity through automation rather than human intervention.
3Manufacturing precision
If multiple nozzles are used for defect repair, then repair precision is improved, but the device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the repair function into specialized nozzles, each with specific functions. One nozzle is dedicated to depositing material for building layers, while separate nozzles handle defect repair operations. This segmentation allows each nozzle to be optimized for its specific purpose, improving repair precision while managing complexity through functional specialization rather than requiring a single complex multi-functional nozzle.
Solution Approach 2:
The system implements local quality by using different nozzles with different characteristics suited for different tasks. The repair nozzles may have smaller orifices for precise defect filling, while the main deposition nozzle is optimized for rapid layer building. Each nozzle is configured with local quality characteristics appropriate to its specific function, improving overall repair precision without requiring all nozzles to be complex multi-functional devices.
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 enables the real-time detection and repair of material defects, reducing the number of scrapped parts and saving time and material by allowing for the identification and correction of defects during the manufacturing process, thereby improving the efficiency and quality of additive manufacturing.
Implementation Method 1
depositing at least one layer of material on a support for the manufacture of the part
Implementation Method 2
scanning said at least one layer, deposited in step a), to acquire topographical data on said at least one layer
Implementation Method 3
repairing said at least one lack of material defect by adding material
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method for repairing a part during layer-by-layer additive manufacturing using an additive manufacturing machine, the additive manufacturing being material extrusion printing, the method comprising the following steps: a) depositing at least one layer of material on a support (2) for manufacturing the part (P), b) detecting at least one unfilled finish if one or more defects of this type are present on the at least one layer, c) repairing said at least one unfilled finish by adding material, d) repeating steps a), b) and optionally c) until the part (P) is produced.