Freeform Sintering Compensation for Dimensional Accuracy
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Solution Overview
Problem
Existing freeform sintering and melting systems using high-energy beams, such as laser or electron beams, face challenges in achieving precise dimensional accuracy, particularly in dental product manufacturing, where tolerances of less than one tenth of a millimeter are required, due to manufacturing-related effects like melting spherules and thermal stresses.
Innovation Solution
A method and device that determine a compensation data set or function to account for manufacturing-related effects, combining it with the product target geometry data to generate control data sets for beam guidance, which includes considering parameters like material properties, beam power, and geometry to adjust for thickness and stress-related inaccuracies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If freeform sintering and melting by high-energy beam is used to produce products layer by layer, then manufacturing flexibility and design freedom are improved, but dimensional accuracy and precision deteriorate due to melting spherules and thermal stresses
Solution Approach 1:
The invention applies preliminary action by calculating compensation values before the actual sintering/melting process. The system pre-determines the geometry of the final product, identifies regions where melting spherules will form, and calculates compensation values in advance to adjust the layer geometry, thereby preventing dimensional inaccuracies before they occur during manufacturing
Solution Approach 2:
The invention implements preliminary anti-action by introducing compensation values that counteract the anticipated harmful effects of melting spherules and thermal stresses. The system proactively applies geometric compensations to inclined sections and surfaces before manufacturing, effectively neutralizing the anticipated dimensional deviations caused by the layer-by-layer sintering/melting process
2Adaptability or versatility
If layer-by-layer construction is used to build products, then complex geometries can be produced, but thermal stresses cause deformations and reduce dimensional accuracy
Solution Approach 1:
The system performs preliminary calculation of thermal stress effects and deformation patterns before manufacturing begins. By simulating and identifying stress-prone regions in advance, the system pre-adjusts the digital model to compensate for anticipated thermal deformations, maintaining dimensional accuracy despite the inherent thermal stresses of layer-by-layer construction
Solution Approach 2:
The invention applies parameter changes by modifying geometric parameters of the digital model based on calculated compensation values. The system adjusts dimensions, angles, and surface geometries of inclined sections to account for thermal expansion and stress-induced deformations that will occur during the layer-by-layer manufacturing process
3Strength
If high-energy beam sintering and melting is applied, then material bonding is achieved, but melting spherules form in inclined sections causing thickness errors
Solution Approach 1:
The invention implements local quality by applying compensation values specifically to inclined sections and surfaces where melting spherules are likely to form, rather than uniformly to the entire product. The system identifies local geometric features (inclined planes, surfaces) and applies targeted compensation to these specific regions, preserving material bonding quality while correcting local thickness inaccuracies
Solution Approach 2:
The invention replaces mechanical measurement and correction methods with a computational approach. Instead of physically measuring and mechanically adjusting each layer for thickness accuracy, the system uses digital modeling and algorithmic calculation to pre-determine compensation values, substituting computational processing for traditional mechanical correction methods
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 significantly enhances the dimensional accuracy of products by compensating for manufacturing-related effects, nearly eliminating errors in product dimensions, especially in inclined sections and reducing thermal stress-induced deformations.
Implementation Method 1
a high-energy beam, e.g. a laser beam or electron beam, that irradiates a material—generally present in powder form—section by section, which heats and melts the material
Implementation Method 2
a high-energy beam, e.g. a laser beam or electron beam, that irradiates a material—generally present in powder form—section by section, which heats and melts the material
Implementation Method 3
freeform sintering and/or freeform melting by means of a high-energy beam
Implementation Method 4
heats and melts the material so that it bonds to the adjacent material
Implementation Method 5
the layer-by-layer construction and the bonding of layers at different temperatures will give rise to stresses within the layers due to different thermal expansion of the different layers
Data Source
AI summary
A method and apparatus used to produce control data for building up a product layer by layer using freeform sintering and/or melting with a high energy beam. The correspondingly controlled apparatus for production of the products is further disclosed. The high energy beam is applied under the guidance of the control data set. Before beginning the freeform sintering and/or freeform melting, a compensation data set and/or a compensation function to compensate for manufacturing related effects caused by the sintering and/or melting is determined. The control data set is based upon a product target geometry data set and the compensation data set and/or the compensation function.