Additive Manufacturing Autozoning for Stress-Based Print Parameters
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Solution Overview
Problem
Conventional additive manufacturing processes use a single, constant set of print parameters for an entire part, leading to over-design and increased production time and costs due to high-fidelity parameters being applied uniformly, even where they are not necessary, while printing with low-fidelity parameters may compromise part quality.
Innovation Solution
A system and methodology to automatically determine and apply different print parameters based on analytical and numerical results for each portion of a part, allowing for varied laser scan speeds, hatch spacing, and other parameters on a granular level, ensuring optimal material properties and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-fidelity print parameters are applied uniformly across the entire part, then part quality and material properties are ensured, but production time and costs increase due to over-design
Solution Approach 1:
The part is divided into multiple zones based on stress analysis results, with each zone assigned appropriate print parameters. High-fidelity parameters are applied only to high-stress zones, while low-stress zones use optimized parameters, eliminating the need for uniform high-fidelity printing across the entire part.
Solution Approach 2:
Different print parameters are assigned to different regions of the part based on local stress requirements. Critical high-stress areas receive high-fidelity parameters to ensure quality, while non-critical areas use parameters optimized for productivity, achieving local optimization rather than uniform application.
2Reliability
If high-fidelity print parameters are used for the entire part, then all portions meet minimum design specifications, but costs increase due to unnecessary application in low-stress areas
Solution Approach 1:
The part is segmented into zones based on stress analysis, allowing differentiation between critical and non-critical areas. This segmentation enables cost-effective manufacturing by applying high-fidelity parameters only where necessary for reliability.
Solution Approach 2:
Print parameters are tailored to local stress conditions, with high-fidelity parameters applied only to high-stress zones requiring strict design specification compliance. Low-stress zones use cost-optimized parameters, reducing overall manufacturing costs while maintaining required reliability.
3Device complexity
If a single set of print parameters is used for the entire build, then the process is simple and consistent, but productivity is reduced due to inability to optimize for different part regions
Solution Approach 1:
Stress analysis and zone identification are performed in advance before the printing process. This preliminary action enables the system to automatically select appropriate parameters for each zone without requiring complex real-time adjustments during printing, maintaining simplicity while enabling productivity optimization.
Solution Approach 2:
The system dynamically selects print parameters based on the spatial location and stress characteristics of different part regions. This dynamic parameter adjustment allows optimization for each zone while maintaining overall process consistency through automated control.
Data Source
AI summary
A method, medium, and system to automatically determine parameter sets for an additive manufacturing (AM) of a part, the method including executing a load analysis on a model of a part to emulate a load on each of a plurality of regions of the part; determining a representation of the model of the part as a plurality of discrete three-dimensional (3D) volume elements; determining, based on an output of the load analysis, a life or material property value to assign to each of the plurality of 3D volume elements; automatically determining an assignment of one of a plurality of additive manufacturing (AM) print parameter sets to each of the plurality of 3D volume elements; and saving a record of the determined assignments of the AM print parameter sets to each of the plurality of 3D volume elements.