Determining build orientation to minimize thermal distortion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for determining build orientation in additive manufacturing to minimize thermal distortion are time-consuming, inaccurate, and computationally inefficient, often requiring significant resources.
Innovation Solution
An algorithm using a momentum of inertia based objective function to determine the optimal build orientation by calculating a proxy for thermal distortion, reducing the need for actual thermal distortion calculations and minimizing computational resources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional methods are used to predict actual thermal distortion before the build, then measurement precision is improved, but loss of time and computational resources increases
Solution Approach 1:
The patent creates a simplified proxy model (copy) of the thermal distortion calculation using momentum of inertia principles. Instead of performing complete thermal distortion simulations, the system uses a simplified objective function that copies the essential behavior of thermal distortion through momentum calculations, achieving comparable predictive accuracy with dramatically reduced computational time
Solution Approach 2:
The patent replaces the complex thermal-mechanical simulation system with a pure mechanical momentum of inertia calculation system. By substituting thermal field calculations with mechanical rotation and inertia tensor calculations, the system achieves the same predictive goal through a computationally simpler mechanical analogy
2Measurement precision
If conventional methods are used to predict actual thermal distortion before the build, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts only the essential elements needed for thermal distortion prediction from the complete thermal simulation process. By taking out and isolating the momentum of inertia calculations as a separate, simplified objective function, the system removes unnecessary computational complexity while retaining the core predictive capability
Solution Approach 2:
The patent creates a simplified proxy model (copy) of the thermal distortion calculation using momentum of inertia principles. Instead of performing complete thermal distortion simulations, the system uses a simplified objective function that copies the essential behavior of thermal distortion through momentum calculations, achieving comparable predictive accuracy with dramatically reduced computational time
3Measurement precision
If actual thermal distortion calculations are performed, then measurement precision is improved, but productivity decreases
Solution Approach 1:
The patent creates a simplified proxy model (copy) of the thermal distortion calculation using momentum of inertia principles. Instead of performing complete thermal distortion simulations, the system uses a simplified objective function that copies the essential behavior of thermal distortion through momentum calculations, achieving comparable predictive accuracy with dramatically reduced computational time
Solution Approach 2:
The patent performs preliminary calculations of the momentum of inertia and inertia tensors before the actual build process. By pre-computing these mechanical properties and establishing the objective function in advance, the system enables rapid determination of optimal build orientations without performing time-consuming thermal simulations during the build preparation phase
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 method efficiently determines the optimal build orientation in under 0.05 seconds per iteration, significantly faster than conventional methods, while accurately predicting thermal distortion.
Implementation Method 1
The algorithm includes a momentum of inertia based objective function, wherein the output (a numerical value) of the objective function can be used as a proxy for thermal distortion
Data Source
AI summary
Embodiments of the systems and methods disclosed herein can related to an additive manufacturing process involving the use of an algorithm to determine the optimal build orientation of a build that will result in minimal thermal distortion during the build. The algorithm includes a momentum of inertia based objective function, wherein the output of the objective function can be used as a proxy for thermal distortion. In some embodiments, objective function can be configured as a mathematical matrix with mathematical variables modeling rotation angles of a build. The rotation angles can be in the x-, y-, and/or z-geometric planes of the build with respect to the build plate. An objective function output can be calculated for each iterative rotation. The minimum objective function output can be used as the rotation representing the orientation that would result in minimal thermal distortion.