3D Skeleton Mesh Comparison for Additive Manufacturing Distortion
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Solution Overview
Problem
Traditional spatial difference measurement methods in additive manufacturing are unreliable and inaccurate due to reliance on manual selection of reference points, leading to significant variations in measurement results.
Innovation Solution
A method that generates key features of nominal and actual 3D models using skeleton-based finite element meshes, allowing for the comparison of these features to measure spatial differences, which can be used to modify additive manufacturing processes in real-time for distortion compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional manual reference point selection methods are used, then the measurement process is simple to operate, but the measurement precision and reliability deteriorate due to significant variations caused by slight changes in reference selection
Solution Approach 1:
The patent introduces a skeleton-based finite element mesh as an intermediary structure between the nominal 3D model and the actual manufactured model. This mesh serves as a standardized reference framework that eliminates the need for manual reference point selection, thereby improving measurement precision while maintaining systematic operation.
Solution Approach 2:
The patent transforms the measurement approach by changing from discrete reference point coordinates to a continuous finite element mesh parameterization. This parameter transformation enables automated comparison of spatial differences through systematic node coordinate analysis, improving both precision and reliability.
2Reliability
If automated skeleton-based finite element mesh method is used, then the measurement precision and reliability improve, but the device complexity and computational requirements increase
Solution Approach 1:
The patent segments the 3D model into a finite element mesh structure, dividing the continuous geometry into discrete elements with defined nodes. This segmentation creates a standardized framework that enables reliable automated comparison while reducing the complexity of direct surface-to-surface analysis.
Solution Approach 2:
The patent creates a digital skeleton-based finite element mesh copy of the nominal model that serves as a reference framework. This copied structure can be automatically compared with the actual model's mesh, improving reliability through systematic node-to-node comparison without requiring complex manual alignment procedures.
3Manufacturing precision
If traditional surface point distance comparison is used, then the measurement process is fast, but the manufacturing precision deteriorates due to inability to accurately detect spatial differences for distortion compensation
Solution Approach 1:
The patent performs preliminary action by pre-generating the skeleton-based finite element mesh from the nominal 3D model before the actual manufacturing process. This pre-established reference framework enables rapid automated comparison during or after manufacturing, improving manufacturing precision through real-time feedback without adding significant measurement time.
Solution Approach 2:
The patent implements a feedback mechanism where the spatial differences measured through skeleton-based finite element mesh comparison are used to detect and compensate for manufacturing distortions. This closed-loop feedback system continuously improves manufacturing precision by adjusting parameters based on measured deviations from the nominal model.
Data Source
AI summary
A spatial difference measurement method, can include generating first key features of a first skeleton of a nominal 3D model of an object and extrapolating the first key features onto the nominal 3D model. The method can include creating an actual 3D model of the object during or after a construction process (real or simulated). The method can include generating second key features of a second skeleton of the actual 3D model of the object and extrapolating the second key features onto the actual 3D model of the object. The method can include comparing the first key features extrapolated on the nominal 3D model to the second key features extrapolated on the actual 3D model to determine one or more distances between the first and second key features to measure a spatial difference between the nominal 3D model and the object during or after construction.