Scanning print bed and part height in 3D printing

Patent metadata

Field	Value
Publication number	US-10953609-B1
Application number	US-201715459965-A
Country	US
Kind code	B1
Filing date	Mar 15, 2017
Priority date	Mar 22, 2013
Publication date	Mar 23, 2021
Grant date	Mar 23, 2021

Abstract

In in-process inspection or calibration of a print bed or 3D printed part with a 3D printer, toolpaths defining printing material shells for deposition by a 3D printer are compared to surface profile scans from a range scanner to identify differences between the print bed, instructed deposition and the measured result, permitting pausing or alteration of the toolpaths or printing process.

First claim

What is claimed is:

1. A method for in-process inspection of a 3D printed part with a 3D printer, comprising:
slicing a three dimensional model to define a plurality of shell volumes;
for one or more shell volumes, generating a toolpath for depositing a printing material shell corresponding to the shell volume;
transmitting, together with an identification, the toolpaths defining the printing material shells for deposition by a 3D printer;
receiving, together with the identification, from the 3D printer a scanned surface profile of a printing material shell;
computing a process inspection including, according to the identification a comparison between the received scanned surface profile and a toolpath defining a printing material shell; and
displaying, according to the identification, a graphic comparison between the received scanned surface profile and the corresponding toolpath defining a printing material shell, the graphic comparison including an overlay in which the scanned surface profile is contrasted with the corresponding toolpath defining a printing material shell.

2. The method according to claim 1 , further comprising transmitting, together with the identification, a selection of printing material shells to be scanned to generate a plurality of scanned surface profiles corresponding to toolpaths defining the selected printing material shells.

3. The method according to claim 1 , further comprising receiving a definition of a boundary shape.

4. The method according to claim 3 , further comprising monitoring the boundary shape.

5. The method according to claim 4 , further comprising transmitting a signal to change a toolpath when a threshold representative of the boundary shape is crossed.

6. The method according to claim 5 , further comprising, for a subsequent printing session, slicing a three dimensional model to define a plurality of shell volumes from the changed toolpaths.

7. The method according to claim 6 , further comprising, for a subsequent printing session, depositing the printed material differently such that the deposited material fits within the boundary shape.

8. The method according to claim 1 , further comprising visually contrasting the scanned surface profile to distinguish the toolpath.

9. The method according to claim 1 , wherein the visual contrast comprises the scanned surface profile being partially transparent.

10. A method for in-process inspection of a 3D printed part with a 3D printer, comprising:
slicing a three dimensional model to define a plurality of shell volumes;
for one or more shell volumes, generating a toolpath for depositing a printing material shell corresponding to the shell volume;
transmitting, together with an identification, the toolpaths defining the printing material shells for deposition by a 3D printer;
receiving, together with the identification, from the 3D printer a scanned surface profile of a printing material shell;
computing a process inspection including, according to the identification, a comparison between the received scanned surface profile and a toolpath defining a printing material shell;
receiving a definition of a boundary shape, the boundary shape comprising a boundary primitive including at least one of a circle, a cylinder, a line, a plane, a polygon, or a prism polyhedron;
comparing at least two of the boundary shape, the received scanned surface profile, and the toolpath defining the printing material shell; and
transmitting a signal to change a toolpath when a threshold representative of the boundary shape is crossed.

11. The method according to claim 10 , further comprising acquiring user input to generate the definition of the boundary shape.

12. The method according to claim 10 , further comprising generating the boundary shape from one of the three dimensional shape, the plurality of shell volumes, the generated toolpaths, or the received scanned surface profiles.

13. The method according to claim 10 , wherein the signal to change the toolpath comprises a signal to pause deposition of a printing material shell.

14. The method according to claim 10 , further comprising:
receiving from the 3D printer a scanned surface profile scanned from a calibration target; and
computing a process calibration including a comparison between a received scanned surface profile and the calibration target.

15. The method according to claim 10 , further comprising:
generating a calibration target toolpath for depositing a calibration target as a 3D printed calibration target;
transmitting the calibration target toolpath defining the 3D printed calibration target for deposition by a 3D printer; and
computing a process calibration including a comparison between the received scanned surface profile of the 3D printed calibration target and the calibration target toolpath.

16. The method according to claim 15 , further comprising:
receiving a tolerance definition for the 3D printed calibration target;
computing a process calibration including toolpath adjustments for toolpaths based on the 3D printed calibration target, the tolerance definition, and the scanned surface profiles of the 3D printed calibration target.

17. The method according to claim 16 , wherein toolpath adjustments correct for an effect of at least one of temperature, humidity or barometric pressure.

18. The method according to claim 16 , wherein toolpath adjustments correct for an effect of at least one of 3D printer component wear, 3D printer component conditioning, or 3D printer material property variation.

Assignees

• Markforged Inc

Inventors

• Mark Gregory Thomas

Classifications

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B29C64/118 Primary

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · CPC title

• G05B19/4099

  Surface or curve machining, making three-dimensional [3D] objects, e.g. desktop manufacturing · CPC title

• B29C64/209

  Heads; Nozzles · CPC title

• B29C64/321

  Feeding · CPC title