Additive Manufacturing Slice Data Distortion Compensation
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Solution Overview
Problem
Additive manufacturing systems often introduce distortions and fail to achieve desired object properties such as surface roughness, accuracy, and strength in generated three-dimensional objects due to geometrical and surface distortions during the solidification process.
Innovation Solution
The system processes slice data based on system feedback, transforming it to compensate for distortions and achieve desired properties by using a processor to modify slice data formats such as vector, contone, halftone, and mask data, incorporating measured feedback and characteristics of the build process, and selectively delivering coalescing and coalescence modifier agents to layers of build material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If slice data is processed using conventional additive manufacturing systems, then three-dimensional objects can be generated, but geometrical and surface distortions occur during the solidification process
Solution Approach 1:
The system performs preliminary transformation on slice data before the actual manufacturing process. The processor transforms slice data representing a slice of a three-dimensional object to compensate for expected distortions during solidification. This preliminary data adjustment ensures that the final object achieves the desired geometrical accuracy and surface quality despite the inherent distortion-prone solidification process.
Solution Approach 2:
The transformation of slice data is based on feedback from measured characteristics of the build process. The system continuously monitors the solidification process and uses this feedback to adjust and transform slice data in real-time, compensating for distortions as they occur and maintaining manufacturing precision throughout the building process.
2Manufacturing precision
If conventional slice data processing is used, then the manufacturing process can proceed, but desired object properties such as surface roughness, accuracy, and strength are not achieved
Solution Approach 1:
The system performs preliminary transformation on slice data before the actual manufacturing process. The processor transforms slice data representing a slice of a three-dimensional object to compensate for expected distortions during solidification. This preliminary data adjustment ensures that the final object achieves the desired geometrical accuracy and surface quality despite the inherent distortion-prone solidification process.
Solution Approach 2:
The transformation of slice data is based on feedback from measured characteristics of the build process. The system continuously monitors the solidification process and uses this feedback to adjust and transform slice data in real-time, compensating for distortions as they occur and maintaining manufacturing precision throughout the building process.
3Manufacturing precision
If real-time slice data transformation is implemented, then object accuracy and surface quality improve, but system complexity increases
Solution Approach 1:
The system replaces complex mechanical adjustment mechanisms with a computational approach. Instead of physically adjusting the manufacturing process to compensate for distortions, the system uses a processor to transform slice data mathematically. This substitution of mechanical systems with computational processing reduces physical complexity while achieving the same or better precision results.
Data Source
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AI summary
A system is provided for processing slice data representing a slice of a three- dimensional object to be generated by an additive manufacturing system. The system includes a processor to perform,when the additive manufacturing system is to generate the slice,a transformation on the slice data based on characteristic data of the additive manufacturing system, the slice data derived from three-dimensional object design data.