Coordinated 3D Printing Controller for Timing Variability
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Solution Overview
Problem
In 3D printing, the lack of coordination between process variables often leads to defects in the formed object, such as deviations from requested geometry parameters and material properties, due to inaccurate timing in processing operations.
Innovation Solution
A controller is used to coordinate the execution of multiple process parameters, such as motion commands of a scanner, focusing elements, and power profiles of a laser, while measuring attributes like temperature in real-time, to achieve a target attribute profile by adjusting control commands and fixing the relative time between these operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple process parameters are controlled independently in 3D printing, then the control system is simpler, but defects occur due to lack of coordination between parameters
Solution Approach 1:
The patent combines multiple independent process parameter controls into a unified coordinated control system. The controller synchronizes motion commands, scanner operations, laser power profiles, and focusing element adjustments as integrated sequences, ensuring that all parameters work together harmoniously to eliminate defects caused by uncoordinated parameter changes.
Solution Approach 2:
The system implements real-time feedback by measuring attributes like temperature during the 3D printing process and using this information to dynamically adjust process parameters. The controller monitors the forming process and coordinates parameter changes based on measured attributes, ensuring quality while maintaining manageable control complexity through adaptive response.
2Manufacturing precision
If process operations are executed without coordinated timing, then the processing speed is faster, but geometry parameters and material properties deviate from requests
Solution Approach 1:
The system performs preliminary coordination of all process parameters before execution. The controller prepares synchronized sequences of motion commands, scanner operations, laser power profiles, and focusing element adjustments in advance, ensuring that timing relationships are established before the actual 3D printing process begins. This pre-coordination enables high-speed execution while maintaining geometric precision.
Solution Approach 2:
The control system dynamically adjusts process parameters in real-time based on measured attributes and process state. The coordinator modifies timing and parameter values during execution to maintain optimal coordination between multiple operations, enabling both high processing speed and precise geometry control through adaptive dynamic adjustment.
3Reliability
If processing operations are delayed to allow coordination, then parameter coordination improves, but the overall processing time increases
Solution Approach 1:
The system maintains continuous coordinated control throughout the entire 3D printing process. The controller continuously synchronizes all process parameters without interruption or delay, ensuring that coordination is maintained throughout material deposition, heating, and solidification. This continuous coordination ensures consistent material properties while minimizing processing time through uninterrupted operation.
Data Source
AI summary
Provided herein are apparatuses, and non-transitory computer readable media regarding at least one controller that provides a capability to coordinate (e.g., integrate) control of a plurality of process variables for forming a 3D object, and methods associated therewith. The process variable may comprise a process parameter of the forming process and/or an attribute of the forming process. The control may comprise an integrated and/or adaptive control scheme of a plurality control variables.