Multi-Layer Molded Article Build with Pre-Corrected Weld Beads
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Solution Overview
Problem
Existing methods for manufacturing additively-manufactured objects face challenges in achieving high deposition accuracy of weld beads due to obstacles from the outer frame, which hinder real-time feedback control and reduce the quality of the manufactured object.
Innovation Solution
A method involving shape pre-measurement, deviation amount calculation, and pre-correction processes to adjust welding conditions based on measurements by a shape sensor, allowing for high-accuracy deposition of weld beads despite the presence of a frame portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If real-time feedback control is performed by measuring weld bead shape with a shape sensor, then deposition accuracy of weld beads is improved, but the outer frame becomes an obstacle that prevents measurement of regions inside the frame
Solution Approach 1:
The patent applies preliminary action by pre-measuring the shape of the base in regions that will be difficult to measure later due to the outer frame obstruction. The shape sensor measures the base shape before the outer frame is constructed, storing this data for later use during feedback control when real-time measurement would be blocked by the frame structure.
2Stability of the object's composition
If the outer frame is built first and then the inner portion is filled, then structural stability is improved, but the outer frame obstructs the shape sensor from measuring regions inside the frame
Solution Approach 1:
The patent performs the measurement action in advance before the outer frame is constructed. The shape sensor captures and stores shape measurement data of the base in regions that will later be obscured by the outer frame. This preliminary measurement ensures that no shape information is lost due to the frame's obstructive position during subsequent construction stages.
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
Enables the production of high-quality additively-manufactured objects with accurate weld bead deposition by pre-measuring and correcting welding conditions, ensuring the internal building portion is built efficiently and accurately.
Implementation Method 1
a shape of the base on which the weld bead layer BL is to be deposited is measured to obtain measurement data
Implementation Method 2
A 3D printer using a metal material is configured to melt a metal powder or a metal wire by using a heat source such as a laser or an arc
Implementation Method 3
deposit the molten metal to manufacture an additively-manufactured object
Data Source
Figure 1
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AI summary
According to the present invention, an internal molding step for molding an internal molded part inside a frame includes: a pre-measurement process for measuring the shape of a substrate on which a weld bead layer is to be laminated; a deviation quantity calculation process for generating a real measurement profile of the substrate from real measurement values of the measured shape of the substrate, determining a plan profile of the substrate from a lamination plan, and calculating a deviation quantity of the real measurement profile from the plan profile; and a pre-correction process for correcting a welding condition of a weld bead constituting the weld bead layer in the lamination plan so as to reduce the deviation quantity when laminating the weld bead layer on the substrate.