Techniques for additive fabrication process optimization and related systems and methods

Patent metadata

Field	Value
Publication number	US-10569526-B2
Application number	US-201615248626-A
Country	US
Kind code	B2
Filing date	Aug 26, 2016
Priority date	Aug 28, 2015
Publication date	Feb 25, 2020
Grant date	Feb 25, 2020

Abstract

According to some aspects, a method of additive fabrication is provided wherein a plurality of layers of material are formed on a surface of a build platform, each layer of material being formed so as to contact a container in addition to the surface of the build platform and/or a previously formed layer of material. The method comprises forming a layer of material in contact with the container and in contact with a previously formed layer of material, and subsequent to the forming of the layer of the material, separating the layer of material from the container by simultaneously applying a first force to the layer of the material in a direction perpendicular to the surface of the build platform, and a second force to the layer of the material in a direction parallel to the surface of the build platform.

First claim

What is claimed is:

1. A method of additive fabrication wherein a plurality of layers of material are formed on a surface of a build platform, each layer of material being formed so as to contact a container in addition to the surface of the build platform and/or a previously formed layer of material, the method comprising:
calculating, using at least one processor, for at least a first layer of the plurality of layers of the material, a first force and a second force to be applied to the first layer subsequent to the first layer being formed, the first and second forces to be applied in directions perpendicular to, and parallel to, the surface of the build platform, respectively, said calculating comprising:
determining an area of at least one portion of the first layer that overhangs a second layer, wherein the plurality of layers comprise a sequence of layers to be formed and the second layer is to be formed earlier in the sequence of layers than the first layer; and
calculating magnitudes of the first force and the second force based at least in part on the determined area of the at least one portion of the first layer that overhangs the second layer;

forming the first layer of material, the first layer of material being in contact with the container and in contact with a previously formed layer of material; and
subsequent to the forming of the first layer of the material, separating the first layer of material from the container by simultaneously applying the calculated first force to the first layer of material and applying the calculated second force to the first layer of material.

2. The method of claim 1 , wherein calculating the magnitude of the first force, by the at least one processor, is further based at least in part on a length of the longest extent of the first layer of the material in the direction parallel to the surface of the build platform.

3. The method of claim 1 , wherein the first layer of material is formed from a liquid photopolymer and wherein calculating the magnitude of the first force and/or the second force, by the at least one processor, is further based at least in part on a viscosity of the liquid photopolymer.

4. The method of claim 1 , wherein calculating the magnitude of the first force and/or the second force, by the at least one processor, is further based at least in part on a measure of fragility of at least a portion of the first layer of material.

5. The method of claim 1 , further comprising applying a preload force in the direction perpendicular to the surface of the build platform prior to application of the first force and second force.

6. The method of claim 5 , further comprising calculating, by the at least one processor, the preload force based at least in part on an area of the first layer of material.

7. The method of claim 1 , further comprising waiting for a predetermined cure time subsequent to the forming of the first layer of the material and prior to actively separating the first layer of material from the container.

8. The method of claim 7 , further comprising calculating, by the at least one processor, the cure time based at least in part on an area of the first layer of material.

9. The method of claim 1 , wherein the method further comprises:
moving a wiper across the surface of the container;
waiting for a predetermined wait time subsequent to moving the wiper across the surface of the container; and
after the predetermined wait time, forming a third layer of material, the third layer of material being in contact with the first layer of material.

10. The method of claim 9 , further comprising calculating, by the at least one processor, the wait time based at least in part on an area of the first layer of material.

11. The method of claim 1 , wherein the first force is applied to the first layer of material by moving the build platform away from the container using at least one actuator.

12. The method of claim 1 , wherein the second force is applied to the first layer of material by moving the container using at least one actuator.

13. The method of claim 1 , further comprising moving a wiper across the surface of the container, wherein the wiper comprises a wiper arm and a wiper blade coupled to said wiper arm using a pivoting coupling.

14. The method of claim 13 , wherein the moving of the wiper across the surface of the container begins during application of the first and second forces and ends after application of the first and second forces has completed.

15. The method of claim 1 , wherein the second layer is to be formed immediately prior to the first layer in the sequence of layers.

16. The method of claim 15 , wherein determining the area of the at least one portion of the first layer that overhangs the second layer comprises determining a Boolean difference between the first layer and the second layer.

17. The method of claim 1 , wherein calculating the magnitudes of the first force and the second force based at least in part on the determined area of the at least one portion of the first layer that overhangs the second layer comprises calculating a numerical factor based on the determined area of the at least one portion of the first layer that overhangs the second layer.

Assignees

• Formlabs Inc

Inventors

• Frantzdale Ben
• Thomas Steven
• Sohn Nicholas M

Classifications

• B29C64/386 Primary

  Data acquisition or data processing for additive manufacturing · CPC title

• B29C64/135

  the energy source being concentrated, e.g. scanning lasers or focused light sources · CPC title

• B29C64/129

  characterised by the energy source therefor, e.g. by global irradiation combined with a mask · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y50/02 Primary

  for controlling or regulating additive manufacturing processes · CPC title