3D Print Parameter Autozoning for Region-Specific AM Quality
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Solution Overview
Problem
Conventional additive manufacturing processes use a single, constant set of print parameters for an entire part, leading to over-design and increased production time and costs due to high-fidelity parameters being applied universally, even where they are not necessary, potentially compromising part quality.
Innovation Solution
A system and methodology to automatically determine and apply different print parameters based on analytical and numerical results for specific regions of a part, allowing for varied laser scan speeds, hatch spacing, and other parameters on a granular level, ensuring optimal material properties and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single, constant set of high-fidelity print parameters is used for the entire part, then all portions of the part meet minimum design specifications, but production time increases and productivity decreases
Solution Approach 1:
The patent applies local quality by assigning different print parameters to different regions of the part based on their specific requirements. The system divides the part into multiple regions, each with its own optimized parameter set, allowing critical areas to receive high-fidelity parameters while non-critical areas use faster, lower-fidelity parameters, thereby resolving the contradiction between reliability and productivity
Solution Approach 2:
The patent segments the part into multiple regions based on design specifications and load requirements. By dividing the part into distinct zones with different parameter requirements, the system can apply high-fidelity parameters only where necessary, reducing overall production time while maintaining reliability in critical areas
2Manufacturing precision
If high-fidelity print parameters are applied universally, then part quality is ensured, but material usage increases and costs rise
Solution Approach 1:
The system applies local quality by matching print parameter fidelity to the actual quality requirements of each part region. Critical areas receive high-fidelity parameters ensuring superior quality, while non-critical areas use standard parameters, thereby maintaining overall part quality while reducing unnecessary material usage and associated costs
3Reliability
If design parameters are determined based on maximum loads, then all portions meet design specifications, but over-design occurs in less heavily-loaded portions
Solution Approach 1:
The patent implements local quality by determining design parameters for each region based on its specific load requirements rather than applying maximum load parameters universally. This allows the design to be optimized locally, reducing complexity while maintaining reliability where needed
Data Source
AI summary
A method, medium, and system including determining a material property value to assign to each of the plurality of 3D volume elements, wherein the material property values assigned to the plurality of 3D volume elements are classified into a predetermined number of bins that correspond to a plurality of different additive manufacturing (AM) print parameter sets, generating a plurality of transfer functions to determine relationships between the material property values assigned to the plurality of 3D volume elements and a plurality of desired AM print parameter sets, automatically determining, based on the plurality of transfer functions, an assignment of one of the plurality of different AM print parameter sets to each of the plurality of 3D volume elements, and validating the determined assignments of the plurality of different AM print parameter sets for the plurality of 3D volume elements based on the plurality of transfer functions.