3D Printing Build Bed Lowering Increment Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing 3D printing methods using powder bed fusion face challenges in achieving dimensional accuracy along the layering direction due to thermal deformation and shrinkage, which current digital compensation methods are unable to fully address, leading to oversize objects and reduced yield.
Innovation Solution
A method involving a controller and apparatus that adjusts the increment by which the build bed is lowered during each layer cycle based on empirical data to compensate for thermal shrinkage, ensuring each layer is distributed at the intended thickness, with the increment potentially varying non-linearly over the build process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If digital compensation is applied to account for thermal shrinkage, then dimensional accuracy in the layering direction is improved, but the method cannot fully address thermal deformation effects
Solution Approach 1:
The patent changes the physical parameter of layer thickness to compensate for thermal shrinkage. Instead of using digital compensation that adjusts the model dimensions, the invention physically modifies the layer thickness parameter during the manufacturing process to account for expected shrinkage, thereby achieving dimensional accuracy that digital methods alone cannot provide
Solution Approach 2:
The patent applies preliminary action by pre-heating the powder bed and components before actual manufacturing begins. This preliminary thermal treatment establishes stable thermal conditions that reduce subsequent thermal deformation and shrinkage during the manufacturing process, addressing the limitation of digital compensation methods
2Ease of manufacture
If the build bed is lowered by the intended layer thickness, then the layer distribution process is simple, but thermal shrinkage causes dimensional inaccuracy along the layering direction
Solution Approach 1:
The patent modifies the lowering increment parameter from the intended layer thickness to a compensated value that accounts for thermal shrinkage. This parameter change allows the build bed to be lowered by an adjusted amount that compensates for expected shrinkage, maintaining both process simplicity and dimensional accuracy
Solution Approach 2:
The patent implements feedback by using empirical data from thermal deformation measurements to adjust the lowering increment. The system measures or estimates thermal shrinkage effects and feeds this information back into the control algorithm to dynamically adjust the build bed lowering increment, ensuring dimensional accuracy while maintaining process simplicity
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 reduces deviations in object height along the layering direction, maintaining dimensional accuracy and consistency, thereby improving the final object's dimensions and reducing cosmetic issues associated with thermal treatment variations.
Implementation Method 1
preheating the layer to a preheat temperature
Implementation Method 2
heating a cross section of the object of the layer to at least a sintering temperature to cause the particulate material of the cross section to sinter or melt
Implementation Method 3
heating a cross section of the object of the layer to at least a sintering temperature to cause the particulate material of the cross section to sinter or melt
Implementation Method 4
thermal conditions of powder bed fusion applications can lead to warping and shrinkage
Data Source
AI summary
Provided is a method for the layer-by-layer manufacture of an object from particulate material, the method comprising the steps of: (a) distributing a layer of particulate material over a build bed, the layer forming a build bed surface and having a layer thickness; (b) preheating the layer to a preheat temperature; (c) heating a cross section of the object of the layer to at least a sintering temperature to cause the particulate material of the cross section to sinter or melt; (d) lowering the build bed by an increment; and (e) distributing a further layer of particulate material of substantially an intended layer thickness, the further layer forming the build bed surface; wherein an object layer cycle comprises the steps (b) to (d); and (f) optionally, repeating the object layer cycle until the object is complete; wherein the increment is different to the intended layer thickness. Further provided is a controller for carrying out the method and an apparatus comprising the controller.