3D Print Bed Scanning for In-Process Toolpath Compensation
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Solution Overview
Problem
There is no commercial or experimental technique for inspecting a print bed, build plate, or deposited material during additive manufacturing to calibrate systems or check the properties and dimensions of the 3D printed parts in real-time, leading to potential inaccuracies and defects.
Innovation Solution
A method for in-process inspection of 3D printed parts using a 3D printer that involves slicing a three-dimensional model to define shell volumes, generating toolpaths for printing material shells, and using a rangefinding scanner to scan the surface profiles of the printed material, allowing for comparison with the intended toolpaths and compensation for manufacturing deviations in the print bed and gantry systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If no inspection technique is used during additive manufacturing, then the printing process continues without interruption, but manufacturing precision and reliability deteriorate due to undetected deviations
Solution Approach 1:
The patent implements real-time optical scanning of the print bed and deposited material during additive manufacturing. The scanner captures surface profiles and compares them against the intended toolpath, providing continuous feedback about manufacturing deviations. This feedback loop enables the system to detect inaccuracies immediately while printing continues, resolving the contradiction by maintaining both productivity and precision through monitoring and compensation.
Solution Approach 2:
The system performs preliminary scanning of the print bed surface before printing begins and before each new layer is deposited. By detecting bed flatness issues and gantry deviations in advance, the system can pre-calculate compensation values and adjust subsequent toolpaths proactively. This preliminary action ensures manufacturing precision is maintained throughout the printing process without interrupting productivity.
2Manufacturing precision
If real-time scanning and inspection are implemented, then manufacturing precision and reliability improve, but device complexity increases
Solution Approach 1:
The patent introduces an optical scanner as an intermediary device that non-invasively measures the print bed surface and deposited material. The scanner acts as a mediator between the printing process and the control system, providing measurement data without physically interfering with the printing operations. This intermediary approach enables precision improvement while avoiding direct mechanical complexity in the printing mechanism itself.
Solution Approach 2:
The system replaces complex mechanical measurement devices with optical scanning technology. Instead of using mechanical probes or contact-based measurement systems that would add mechanical complexity, the patent employs non-contact optical methods to detect surface profiles and dimensional deviations. This substitution achieves high manufacturing precision while minimizing the addition of mechanical system complexity.
3Ease of manufacture
If the print bed surface is not scanned and compensated, then the printing process is simpler, but reliability and part quality deteriorate due to bed flatness issues
Solution Approach 1:
The patent performs preliminary scanning of the print bed surface before printing begins. By detecting flatness deviations, warping, or contamination on the print bed in advance, the system can pre-calculate compensation values and adjust the first layer toolpath proactively. This preliminary action ensures reliable first layer adhesion and part quality without making the printing process itself more complex, as the compensation is prepared beforehand.
4Productivity
If manufacturing deviations are not detected mid-print, then the printing process continues uninterrupted, but loss of time occurs due to failed parts requiring reprints
Solution Approach 1:
The patent implements mid-print optical scanning that provides continuous feedback about layer deposition quality and dimensional accuracy. When deviations exceed predetermined thresholds, the system immediately detects the issue and can pause printing or adjust subsequent layers. This feedback mechanism prevents the completion of defective parts, eliminating the time loss associated with reprinting while maintaining high productivity through continuous monitoring and in-process correction.
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 real-time calibration and compensation for manufacturing deviations, improving the accuracy and quality of 3D printed parts by adjusting toolpaths and ensuring precise deposition of printing material shells, thereby enhancing the overall printing process.
Implementation Method 1
A scanned surface profile of a printed material shell may be received, together with the identification, from the 3D printer
Data Source
AI summary
In in-process inspection or calibration of a print bed or 3D printed part with a 3D printer, toolpaths defining printing material shells for deposition by a 3D printer are compared to surface profile scans from a range scanner to identify differences between the print bed, instructed deposition and the measured result, permitting pausing or alteration of the toolpaths or printing process.