Additive Manufacturing Build Characteristic Contribution Profile
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Solution Overview
Problem
Existing additive manufacturing systems lack localized control over build characteristics, leading to undesirable stress or deformation anomalies in components, as altering build parameters for entire components can inadvertently increase stress or deformation in regions of interest.
Innovation Solution
An additive manufacturing system with a control system that generates a model with multiple elements and a region of interest, applies strain loads to elements, and adjusts build parameters based on build characteristic contribution profiles to precisely control build characteristics in specific areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If build parameters are modified for the entire component or region of interest, then build characteristics in the region of interest can be influenced, but stress or deformation in the region of interest increases
Solution Approach 1:
The patent applies local quality by differentiating build parameters across different regions of the component. Instead of applying uniform build parameters to the entire component, the system identifies specific regions contributing to unwanted build characteristics and applies modified parameters only to those regions. This is achieved through regional identification algorithms that analyze build characteristic contribution profiles and selectively adjust parameters for identified regions, thereby improving local build quality without adversely affecting other regions.
Solution Approach 2:
The patent segments the component into multiple regions based on build characteristic contribution profiles. The system divides the component into first regions (contributing to unwanted build characteristics) and second regions (not contributing). This segmentation allows independent control of build parameters for different regions, enabling optimization of specific problem areas without compromising the overall component integrity or other regions.
2Manufacturing precision
If build parameters are altered to reduce stress or deformation, then build characteristics improve, but manufacturing efficiency decreases due to extended process time
Solution Approach 1:
The patent applies partial action by modifying build parameters only for specific regions identified as contributing to unwanted build characteristics, rather than applying modifications to the entire component. This selective approach reduces the overall process time compared to comprehensive parameter modifications, while still achieving the desired improvement in build characteristic quality for the critical regions.
Solution Approach 2:
The system performs preliminary analysis by generating build characteristic contribution profiles before the actual manufacturing process. This preliminary identification of problematic regions allows the system to pre-plan targeted parameter modifications, avoiding unnecessary process extensions and optimizing the manufacturing timeline by addressing only the critical areas that require attention.
Data Source
AI summary
An additive manufacturing system includes a control system communicatively coupled to a consolidation device and configured to control operation of the consolidation device. The control system is configured to generate a model of a component. The model includes a plurality of elements and at least one region of interest. The control system is also configured to apply a strain load to at least one element of the plurality of elements and generate a build characteristic contribution profile for at least one element of the plurality of elements. The build characteristic contribution profile represents an effect of the strain load applied to the at least one element on a build characteristic of at least one location within the at least one region of interest. The control system is further configured to adjust a build parameter for a location within the component relating to the at least one element of the plurality of elements based on the build characteristic contribution profile.