Additive Manufacturing Distortion Compensation via Skeletal Models
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Solution Overview
Problem
Additive manufacturing (AM) processes face significant distortion and residual stress issues due to 'springback' phenomena and material shrinkage during the cooling phase, leading to precision and quality reductions, with current methods failing to account for physical processes and being impractical for complex larger parts.
Innovation Solution
A process distortion compensation system that generates a digital compensation model by determining a digital skeletal model indicating predicted shape and volume changes, using 3D scanning and deformation analysis to create a 3D physical object that compensates for distortions, thereby improving shape accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If current distortion compensation methods are used, then shape accuracy can be improved, but the process becomes expensive and iterative
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing distortion compensation data in lookup tables before actual manufacturing. The system pre-processes the distortion model to create compensation maps that can be quickly applied during production, eliminating the need for expensive iterative calculations during the manufacturing process itself.
Solution Approach 2:
The patent uses copying by creating digital twin models and lookup tables that replicate the distortion behavior. Instead of performing complex calculations on the actual part, the system uses pre-generated digital copies and reference data structures that can be quickly queried and applied, significantly reducing computational complexity during manufacturing.
2Manufacturing precision
If distortion compensation is applied to complex larger parts, then shape accuracy improves, but the current methods become impractical
Solution Approach 1:
The patent applies segmentation by dividing complex large parts into smaller manageable segments or zones. The distortion compensation is calculated and stored for each segment separately, allowing the system to handle complex geometries by breaking them down into simpler components that can be processed independently and then reassembled.
Solution Approach 2:
For complex larger parts, the patent uses copying by creating reusable distortion compensation templates and lookup tables for standardized geometric features. Once distortion characteristics are measured for a particular feature type, the compensation data is copied and applied to all similar features throughout the complex part, dramatically reducing the computational burden.
3Manufacturing precision
If iterative distortion subtraction is performed, then final shape accuracy is achieved, but manufacturing time increases
Solution Approach 1:
The patent eliminates iterative distortion subtraction by performing the distortion compensation calculation in advance and storing the results in lookup tables. During manufacturing, the pre-calculated compensation data is simply queried and applied directly to the model, transforming a time-consuming iterative process into a fast lookup operation.
Solution Approach 2:
The patent replaces the mechanical iterative calculation process with a data-driven lookup system. Instead of repeatedly subtracting computed distortion through complex algorithms, the system substitutes this with direct retrieval of pre-computed compensation values from optimized data structures, dramatically reducing computational time.
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
The system effectively reduces distortion and residual stress in AM products by predicting and compensating for shape and volume changes, enhancing the precision and quality of fabricated parts, particularly for complex larger sizes.
Implementation Method 1
Additive manufacturing (AM) processes face significant distortion and residual stress issues due to 'springback' phenomena and material shrinkage during the cooling phase
Implementation Method 2
Additive manufacturing (AM) processes face significant distortion and residual stress issues due to 'springback' phenomena and material shrinkage during the cooling phase
Data Source
AI summary
An additive manufacturing (AM) system includes a process distortion compensation computing system and an AM peripheral device. The process distortion compensation computing system determines a digital nominal model that represents a physical target object excluding a distortion, and a digital distortion model that represents the physical target object including at least one distortion. The AM peripheral device forms a three-dimensional (3D) physical object based on a digital compensation model. The process distortion compensation computing system also determines a digital skeletal model indicating a predicted change in at least one of the shape and volume of the nominal model, and generates the digital compensation model based on the skeletal model that compensates for the at least one distortion.