Autonomous Mechanical Testing of Additive Manufactured Specimens
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Solution Overview
Problem
Current mechanical testing processes for additively manufactured components are inefficient due to the need for manual handling and separate fabrication of test coupons, which limits rapid data collection and increases costs, especially when dealing with complex geometries and materials like metals, ceramics, and polymers.
Innovation Solution
Implementing an autonomous mechanical testing system using a multi-linked robotic arm with a multi-axis load cell and end effector to apply loads and measure mechanical properties directly on the build plate, allowing for rapid and cost-effective testing of various mechanical properties such as tensile, torsional, and fracture toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling and separate fabrication of test coupons are used, then testing can be performed according to standard procedures, but testing efficiency is low and data collection is slow
Solution Approach 1:
The patent merges the fabrication and testing operations by integrating test coupons directly into the build plate structure. Multiple test coupons are fabricated as integral parts of the build plate in various orientations and positions, eliminating the need for separate handling and setup. The robotic arm performs both fabrication and subsequent testing of these integrated coupons, significantly improving productivity and reducing data collection time.
Solution Approach 2:
The build plate serves multiple functions: it acts as both the manufacturing substrate and the testing fixture. The test coupons are self-contained within the build plate structure, with built-in mounting features that allow direct engagement by the robotic arm. This self-service approach eliminates the need for external fixtures and manual intervention, enabling rapid automated testing.
2Ease of manufacture
If separate fabrication of test coupons is performed, then standardized testing can be conducted, but fabrication costs and time increase
Solution Approach 1:
The patent combines the fabrication of test coupons with the fabrication of the build plate itself. Multiple test coupons are created as integral features during the same additive manufacturing process, eliminating separate fabrication steps. This merging approach maintains standardized testing capabilities while dramatically reducing total fabrication time and cost.
Solution Approach 2:
The build plate is designed as a universal platform that simultaneously serves as the manufacturing substrate and contains multiple test coupons for various testing configurations. This multi-functional design allows a single fabrication process to produce both the build plate and multiple test specimens in different orientations and positions, simplifying the overall manufacturing process.
3Measurement precision
If manual handling of test coupons is required, then precise positioning can be achieved, but operator time and labor costs increase
Solution Approach 1:
The patent replaces manual mechanical handling with an automated robotic arm system. The robotic arm is equipped with sensors and control systems that enable precise positioning and engagement of test coupons. The system uses automated vision or positioning systems to locate coupons on the build plate and accurately apply loads, maintaining measurement precision while eliminating manual labor and increasing throughput.
Solution Approach 2:
The robotic arm acts as an intermediary between the control system and the test coupons. It features an end effector with multi-axis load cells that precisely measure and apply forces to the coupons. This intermediary system provides both the precision of controlled positioning and the speed of automated operation, replacing manual handling while maintaining accuracy.
4Loss of information
If complex geometries are tested using traditional methods, then detailed mechanical properties can be obtained, but testing complexity and cost increase
Solution Approach 1:
The patent uses a robotic arm with multi-axis load cells and sensors to automatically characterize complex geometries. The system can apply various loading conditions (tension, compression, torsion) and track deformation using optical or sensor-based measurement systems. This automated approach captures complete mechanical property data for complex shapes without requiring complex manual testing setups, reducing device complexity while maintaining data completeness.
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 significantly increases testing efficiency, reduces costs, and enables the rapid collection of large data sets, allowing for better understanding of material properties and process optimization, while accommodating complex geometries and stress states.
Implementation Method 1
intermediate the end effector and the multi-linked robotic arm comprises a multi-axis load cell for measuring an applied load
Data Source
AI summary
A process for autonomous mechanical property testing of specimens on a build plate includes fabricating a plurality of the specimens on a build plate, wherein each of the specimens comprises an upper portion and a lower portion integral to the build plate. Each of the upper portions of the specimens on the build plate are sequentially engaged with an end effector on a terminal end of a multi-linked robotic arm, wherein the end effector is configured to engage the upper portion and apply a uni- or multi-modal load, wherein intermediate the end effector and the multi-linked robotic arm comprises a multi-axis load cell for measuring an applied load. The process further includes autonomously calculating one or more mechanical properties from the applied load.