Additive Manufacturing Scan Data Review for Selected Slices
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Solution Overview
Problem
Current software for additive manufacturing takes a long time to automatically determine slices and scan paths, requiring users to wait until the process is complete to review potential issues, such as overhang regions and scan path errors, which can lead to inefficiencies and potential build problems like warping or curling.
Innovation Solution
A device and method that allow users to review and select specific slices during the determination process, enabling the processor to prioritize and display scan data for selected slices while determining others, allowing for real-time review and modification of scan parameters and paths, including temperature predictions and thermal modeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If automatic determination of slices and scan paths is performed for all slices before review, then complete scan data is available for the entire part, but the user must wait until the process is complete to review potential issues
Solution Approach 1:
The patent divides the scan data determination process into individual slice-level units, allowing the system to process and display scan data for selected slices independently rather than requiring completion of all slices. This segmentation enables users to review specific slices of interest without waiting for the entire determination process to complete.
Solution Approach 2:
The patent implements partial action by allowing users to review scan data for a subset of slices (those of interest) before the determination process is complete for all slices. The system prioritizes displaying scan data for selected slices even while continuing to process remaining slices in the background.
2Reliability
If the system processes all slices to completion before allowing review, then all scan data is available, but efficiency is reduced due to mandatory waiting time
Solution Approach 1:
The patent maintains continuous processing by allowing the determination of scan data to proceed in the background for all slices while simultaneously enabling users to review and interact with scan data for selected slices. The process continues without interruption, improving overall productivity while maintaining data reliability.
Solution Approach 2:
The patent enables preliminary review of scan data for selected slices before the complete determination process finishes. Users can perform preliminary assessments and identify issues in critical portions of the part while the system continues processing remaining slices.
3Loss of time
If scan data is determined for selected slices only, then review time is reduced, but thermal modeling accuracy may be compromised
Solution Approach 1:
The patent applies local quality by allowing users to select specific slices of interest for immediate review based on their criticality or importance. The system prioritizes processing and displaying scan data for these locally selected regions while maintaining the option to process remaining slices subsequently, balancing time reduction with thermal modeling accuracy.
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 reduces the time needed to determine acceptable scan data, enables real-time review and adjustment of scan parameters, and improves the accuracy of thermal modeling, thereby minimizing warping and curling issues during the additive manufacturing process.
Implementation Method 1
a laser beam is scanned across portions of the powder layer that correspond to a cross-section (slice) of the part being constructed. The laser beam melts or sinters the powder to form a solidified layer.
Implementation Method 2
The laser beam melts or sinters the powder to form a solidified layer.
Implementation Method 3
US2005/0142024 discloses a scan strategy for reducing thermal loads comprising successively irradiating individual areas of a layer
Data Source
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AI summary
A device and method for generating scan data and/or slice data for use in an additive manufacturing process, in which an energy beam is scanned across layers of flowable material to consolidate the material in a layer-by-layer manner to build a part. The device comprises a display and a processor. The processor is arranged to determine scan data for slices and/or slices of the part to be built in the additive manufacturing process and cause the display to display scan data and/or slices that has been determined whilst determining scan data for other ones of the slices and/or other ones of the slices from the geometric data.