Selective modification of build strategy parameter(s) for additive manufacturing

Patent metadata

Field	Value
Publication number	US-10338569-B2
Application number	US-201715677426-A
Country	US
Kind code	B2
Filing date	Aug 15, 2017
Priority date	Aug 15, 2017
Publication date	Jul 2, 2019
Grant date	Jul 2, 2019

Abstract

A computerized method, system, program product and additive manufacturing (AM) system are disclosed. Embodiments provide for modifying object code representative of an object to be physically generated layer by layer by a computerized AM system using the object code. The computerized method may include providing an interface to allow a user to manually: select a region within the object in the object code, the object code including a plurality of pre-assigned build strategy parameters for the object that control operation of the computerized AM system, and selectively modify a build strategy parameter in the selected region in the object code to change an operation of the computerized AM system from the plurality of pre-assigned build strategy parameters during building of the object by the computerized AM system.

First claim

What is claimed is:

1. A computerized additive manufacturing (AM) system for physically generating an object layer by layer based on object code representative of the object, the object code including a plurality of pre-assigned build strategy parameters for the object that control operation of the computerized AM system, the computerized AM system comprising:
an AM printer including at least two irradiation devices; and
an object code modifier providing an interface to, prior to manufacturing the object, allow a user to manually:
select a region within the object in the object code, the region including a stitching region to be created by the at least two irradiation devices and the build strategy parameter controls operation of the at least two irradiation devices of the AM printer relative to the stitching region; and
selectively modify a build strategy parameter in the selected region in the object code to change an operation of the computerized AM system from the plurality of pre-assigned build strategy parameters during building of the object by the computerized AM system, wherein the build strategy parameter modifying includes modifying a characteristic of a scan vector end gap among a plurality of spaced scan vector end gaps created by the at least two irradiation devices, each scan vector end gap defined between a first melt pool end of a first scan vector formed by the first irradiation device in the stitching region and a second, abutting melt pool end of a different scan vector formed by the second, different irradiation device in the stitching region, wherein the plurality of spaced scan vector end gaps are alternatingly positioned in the stitching region.

2. The computerized AM system of claim 1 , wherein the region extends vertically across a plurality of layers of the object, and the selective modifying includes assigning a first position for the stitching region in a first layer of the object, and assigning a second, different position for the stitching region in a second, different layer of the object.

3. The computerized AM system of claim 2 , wherein the first position of the stitching region in the first layer does not overlap with the second, different position of the stitching region in the second, different layer.

4. The computerized AM system of claim 2 , wherein the first position is on a first lateral side of a centerline of the selected region, and the second, different position is on a second, different lateral side of the centerline of the selected region.

5. The computerized AM system of claim 1 , wherein the build strategy parameter selective modifying includes modifying a position of the stitching region in the region of the layer of the object from the plurality of pre-assigned build strategy parameters.

6. The computerized AM system of claim 1 , wherein the build strategy parameter selective modifying includes modifying a size of the stitching region in the region of the layer of the object from the plurality of pre-assigned build strategy parameters.

7. The computerized AM system of claim 1 , wherein the build strategy parameter selective modifying includes modifying a shape of the stitching region in the region of the layer of the object from the plurality of pre-assigned build strategy parameters.

8. The computerized AM system of claim 1 , wherein the stitching region has a centerline defining a first half and a second half of the stitching region in the region, and wherein the build strategy parameter modifying includes alternatingly positioning the plurality of spaced, scan vector end gaps in the first half and the second half of the stitching region.

9. The computerized AM system of claim 1 , wherein the stitching region has a centerline defining a first half and a second half of the stitching region in the region, and wherein the build strategy parameter modifying includes randomly selecting a position of the plurality of spaced scan vector end gaps between the first half and the second half of the stitching region.

10. The computerized AM system of claim 1 , wherein the build strategy parameter modifying includes modifying a size of at least one of the plurality of spaced, scan vector end gaps.

11. The computerized AM system of claim 1 , wherein the plurality of pre-assigned build strategy parameters includes at least one pre-assigned irradiation device assignment for each layer of the object, and
wherein the selectively modifying includes changing the at least one pre-assigned irradiation device assignment within the region.

12. The computerized AM system of claim 1 , wherein the AM printer includes at least one irradiation device.

13. The computerized AM system of claim 12 , wherein the plurality of pre-assigned build strategy parameters includes a set of preset scan vector parameters for each layer of the object, and
wherein the build strategy parameter selective modifying includes changing at least one scan vector parameter from the set of preset scan vector parameters for the region of the layer of the object.

14. The computerized AM system of claim 12 , wherein the build strategy parameter modifying includes changing a beam size of the at least one irradiation device for the region from the plurality of pre-assigned build strategy parameters.

15. The computerized AM system of claim 1 , wherein the selected region is defined by at least one scan vector used to build the object in the object code.

16. The computerized AM system of claim 1 , wherein the selected region is defined by one of an areal space within each of at least one layer of the object in the object code, or a volume of the object within the object code.

17. The computerized AM system of claim 1 , wherein the region includes a plurality of regions, and the layer includes a plurality of layers, each region including a selectively modified build strategy parameter.

18. The computerized AM system of claim 1 , wherein the object code includes a layer by layer representation of the object, each layer to be sequentially, physically generated by the AM printer.

19. The computerized AM system of claim 1 , wherein modifying the build strategy parameter includes:
positioning a first one of the plurality of spaced vector end gaps in a first portion of the stitching region, and
positioning a second one of the plurality of spaced vector end gaps in a second portion of the stitching region, such that the first one of the plurality of spaced vector end gaps does not overlap with the second one of the plurality of spaced vector end gaps.

20. The computerized AM system of claim 1 , wherein the modifying the build strategy parameter includes re-assigning the first scan vector from the first irradiation device to the second, different irradiation device.

Assignees

• Gen Electric

Inventors

• Crear Donnell Eugene
• Graham Michael Evans
• Jia Tao
• Shalaby Mohammed Mounir

Classifications

• B22F12/47

  parallel to the deposition plane · CPC title

• B22F12/90

  Means for process control, e.g. cameras or sensors · CPC title

• B22F12/67

  Blades · CPC title

• B22F12/45

  Two or more · CPC title

• B22F10/366

  Scanning parameters, e.g. hatch distance or scanning strategy · CPC title