Additive Manufacturing Scan Data Review for Thermal Load Control
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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 end of the process to review potential issues, such as overhang regions and scan path errors, which can lead to warping and curling of parts due to excessive thermal loads.
Innovation Solution
A device and method that allow users to review and select specific slices for review while the processor determines scan data for other slices, enabling the display of scan data in real-time during the process, allowing for immediate identification and modification of scan parameters and paths to prevent thermal issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the processor determines scan data for all slices before display, then the completeness of scan data is improved, but the time required for users to review and identify issues worsens
Solution Approach 1:
The patent divides the scan data determination process into individual slice-level tasks that can be executed and displayed independently. The processor determines scan data for slices in parallel or in a prioritized sequence, allowing users to review individual slices as they are determined rather than waiting for complete processing of all slices. This segmentation enables early detection of issues in critical slices while maintaining overall data completeness.
Solution Approach 2:
The system performs preliminary determination and display of scan data for slices that are most critical or likely to contain issues (such as overhang regions or complex geometries) before completing processing of all slices. This allows users to review and potentially modify scan parameters for problematic areas early in the process, reducing total review time while maintaining precision for critical regions.
2Manufacturing precision
If the system processes all slices sequentially, then the accuracy of scan data determination is improved, but the productivity of the additive manufacturing preparation worsens
Solution Approach 1:
The scan data determination process is segmented into independent slice-level tasks that can be processed in parallel. The processor divides the workload into multiple concurrent processes, each handling specific slices, thereby maintaining accurate determination for each slice while significantly reducing total processing time through parallel execution.
Solution Approach 2:
The system implements a multi-level processing approach where critical slices are processed with full accuracy while less critical slices can be processed with reduced detail or in parallel with lower priority. This partial action approach ensures high accuracy for important regions while maintaining overall productivity through differentiated processing levels.
3Reliability
If users must wait until the end of the determination process to review slices, then the thoroughness of issue identification is improved, but the time to detect and correct thermal load problems worsens
Solution Approach 1:
The system performs preliminary determination and display of scan data for slices, particularly those likely to contain thermal load issues such as overhangs or complex geometries, before completing processing of all slices. Users can review and identify potential problems early in the process, allowing timely correction of scan parameters to prevent thermal issues before actual manufacturing begins.
Solution Approach 2:
The system provides continuous feedback to users by displaying determined scan data for slices as processing progresses. Users can review displayed slices, identify issues, and provide feedback for modification. The system then reprocesses affected slices with corrected parameters, creating a feedback loop that enables early detection and correction of problems while maintaining thoroughness through iterative review.
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 by allowing users to review and modify scan parameters in real-time, thereby minimizing thermal loads and improving the accuracy and stability of the additive manufacturing process.
Implementation Method 1
the processor arranged to determine scan data for slices of the part to be built and cause the display to display scan data that has been determined for at least one of the slices whilst the scan data for other ones of the slices is being determined
Data Source
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 includes 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.