Additive Manufacturing Data Visualization System
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Solution Overview
Problem
Current additive manufacturing (AM) processes lack effective visualization tools for users to understand potential object defects, support structure effectiveness, melt pool consistency, and manufacturing process efficiency, hindering the ability to optimize the AM process and machine performance.
Innovation Solution
A system and method that collect and process data from AM processes, transforming it into visualization data compatible with computer-aided design specifications, allowing users to render visual depictions of specific aspects of the manufacturing process and objects, enabling better understanding and optimization of the AM process and machine performance through user-controlled queries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If additive manufacturing processes are used to fabricate complex objects, then design freedom and geometric complexity are improved, but the ability to visualize and understand process data and potential defects deteriorates
Solution Approach 1:
The patent creates a visual copy or representation of the additive manufacturing process data and object geometry. The system generates visual depictions that replicate the three-dimensional object structure and overlays process information, allowing users to view and analyze data without altering the actual manufacturing process. This copying approach enables comprehensive visualization while maintaining the integrity of the original complex geometric data.
2Manufacturing precision
If real-time monitoring of AM process parameters is implemented, then manufacturing precision and defect detection are improved, but device complexity increases
Solution Approach 1:
The patent implements a multi-functional visualization system that handles multiple types of process data (temperature, laser parameters, mechanical properties) through a single integrated platform. The system can display various aspects of the additive manufacturing process including real-time monitoring, historical data analysis, and defect detection all within one interface, reducing the need for multiple separate monitoring devices and simplifying the overall system architecture.
3Reliability
If comprehensive process data is collected during AM, then reliability and quality understanding are improved, but loss of time for data processing increases
Solution Approach 1:
The patent performs preliminary organization and structuring of process data during the manufacturing process itself. The system pre-processes and categorizes data as it is generated, creating ready-to-analyze visual representations that can be immediately viewed and interpreted. This preliminary action reduces the need for extensive post-processing and allows users to quickly understand quality metrics and potential defects without significant time delays.
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
Provides users with visual information to identify and address potential defects, improve AM machine processing, and enhance the quality of the workpieces by allowing for real-time monitoring and adjustment of process parameters, thereby optimizing the AM process and reducing defects.
Implementation Method 1
using a powerful heat source (such as a laser beam, an electron beam, plasma welding arc, or the like) to melt and deposit a layer of that material
Implementation Method 2
Selective Laser Sintering (SLS) is an example of an additive manufacturing technique. SLS utilizes a laser (for example, a carbon dioxide laser) to fuse small particles of plastic, metal, ceramic, or glass powders into a mass that has a desired three-dimensional shape.
Implementation Method 3
With the advent of high-power lasers (in the range of 100's to 1000 Watts or higher), Direct Metal Laser Melting (DMLM) is typically utilized to completely melt metal particles during 3-D manufacturing of work pieces. In some implementations, an electron beam metal powder bed machine (EB) DMLM preheats the bulk powder material in the powder bed to a temperature somewhat below its melting point
Implementation Method 4
With the powder acting as a thermal insulator in the DMLM process, it is necessary to try to control the thermal conductivity in the subsurface structure in order to keep the melt pool constant.
Data Source
AI summary
Systems, apparatus and methods provide a visual representation to users of data collected from a three dimensional manufacturing process, such as an additive manufacturing (AM) process. In an embodiment, a user device receives process data associated with a three dimensional manufacturing process, transforms the process data into visualization data compatible with a computer-aided design specification, receives a Boolean query, and then renders, in response to the Boolean query, a visual depiction on a display screen of at least one aspect of the three dimensional manufacturing process and/or the three dimensional manufacturing apparatus and/or a object being manufactured.