Automated Lattice Structure Defect Detection via CT Analysis
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Additively manufactured lattice structures are challenging to evaluate for defects, particularly in strut morphology, due to their complexity and the large number of struts, which makes manual evaluation impractical and existing imaging technologies inadequate for detecting internal defects.
Innovation Solution
The proposed solution involves analyzing computed tomography (CT) data of lattice structures by filtering to identify nodes, applying a thinning algorithm to gather three-dimensional path information of struts, and comparing cross-sections and struts from the CT data to a predefined three-dimensional mesh to detect defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If basic imaging technology is used to evaluate lattice structures, then the evaluation process is simple, but only outer surface struts can be detected and internal defects are missed
Solution Approach 1:
The patent transitions from two-dimensional surface imaging to three-dimensional volumetric imaging using computed tomography. This dimensional change enables detection of internal defects within the lattice structure that cannot be observed from external surfaces alone, directly resolving the contradiction between detection capability and imaging complexity.
2Measurement precision
If manual evaluation of struts is performed, then detailed inspection is possible, but the process becomes impractical due to the large number of struts
Solution Approach 1:
The patent replaces manual mechanical evaluation with automated computational analysis. A computer-implemented method processes the three-dimensional mesh data and computed tomography data to automatically identify and compare struts, eliminating the need for manual inspection of thousands of individual struts while maintaining detection accuracy.
Solution Approach 2:
The patent creates a digital three-dimensional mesh copy of the lattice structure design and compares it with the actual computed tomography scan data. This copying approach enables automated comparison of numerous struts against their nominal designs, significantly improving evaluation efficiency while maintaining precision.
3Adaptability or versatility
If the number of struts in a lattice structure increases to provide complex solutions, then functional capabilities improve, but defect evaluation becomes exceedingly difficult
Solution Approach 1:
The patent replaces difficult manual defect evaluation with automated computational methods that can efficiently process large numbers of struts. The computer-implemented comparison between three-dimensional mesh data and computed tomography data enables systematic evaluation of complex lattice structures with thousands of struts, making defect detection feasible despite increased structural complexity.
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 enables effective identification of defects within lattice structures by overcoming the limitations of manual evaluation and basic imaging technologies, providing a comprehensive evaluation of both internal and external struts.
Implementation Method 1
receiving a set of computed tomography data including a volumetric representation of the lattice structure
Implementation Method 2
scanning the lattice structure using a computed tomography scanner to obtain the set of computed tomography data
Data Source
AI summary
Systems, methods, and computer-readable media for evaluating a set of computed tomography data associated with a lattice structure. The lattice structure may be additively manufactured. The computed tomography data may be segmented using a filter for identifying blob-like structures to identify nodes present within the lattice structure. A three-dimensional path traversal is applied to volumetric data to identify a plurality of struts within the lattice structure that are compared to corresponding struts within a set if three-dimensional mesh data of the lattice structure to identify defective struts. Further, two-dimensional slices may be extracted from each of the computed tomography data and the mesh data and compared to identify one or more inconsistencies indicative of defects within the lattice structure.