Adaptive 3D printing

Patent metadata

Field	Value
Publication number	US-10996652-B2
Application number	US-201815959063-A
Country	US
Kind code	B2
Filing date	Apr 20, 2018
Priority date	Apr 21, 2017
Publication date	May 4, 2021
Grant date	May 4, 2021

Abstract

Methods provide for fabricating objects through additive manufacturing in a manner that compensates for deformations introduced during post-print processing, such as sintering. An initial model may be divided into a plurality of segments, the initial model defining geometry of an object. For each of the segments, modified geometry may be calculated, where the modified geometry compensates for a predicted deformation. Print parameters can then be updated to incorporate the modified geometry, where the print parameters define geometry of the printed object (e.g., configuration settings of the printer, a tool path, an object model). The object may then be printed based on the updated print parameters.

First claim

What is claimed is:

1. A method of printing an object, comprising:
dividing an object model into a plurality of slices with a thickness in a Z-direction, the model defining a first geometry of the object;
for each of the plurality of slices:
calculating, for each of the plurality of slices, a measure of stress using a cross-sectional area of the slice and calculated weight of material residing atop the slice according to

σ
=

g
·

m

above
⁢

⁢
segment

A
segment

;

 and
predicting a deformation upon the slice will occur according to the measure of stress as a result of a sintering process following deposition of all the layers;
calculating a modified geometry for the slice, the modified geometry compensating for the deformation;

calculating a second geometry of the object from the collective of the modified geometries for each of the slices, the second geometry corresponding to a print geometry for the object; and
printing the object based on the second geometry.

2. The method of claim 1 , wherein the weight of material corresponds to weight of all material residing atop said slice.

3. The method of claim 1 , wherein the measured stress is associated with a corresponding compression force.

4. The method of claim 3 , wherein the corresponding compression force is associated with the deformation.

5. The method of claim 1 , wherein the measure of stress is calculated based on a location of a center of gravity of slices located above the slice.

6. The method of claim 1 , wherein before the printing step, the method further comprises generating a correction model of the object.

7. The method of claim 6 , wherein the correction model defines the modified print geometry of the object.

8. The method of claim 1 , wherein the printing comprises extruding feedstock.

9. The method of claim 8 , wherein the feedstock is extruded at a temperature between 160-250 degrees Celsius.

10. A method of printing an object, comprising:
dividing an object model into a plurality of slices with a thickness in a Z-direction, the object model defining a first geometry of the object;
calculating, for each slice from the plurality of slices:
a cross-sectional area in an X-Y plane;
a weight of material residing atop each slice;
a measure of stress using the calculated cross-sectional area and the calculated weight of material residing atop each slice according to

σ
=

g
·

m

above
⁢

⁢
segment

A
segment

;

 and
a predicted compression force upon the slice resulting from the measure of stress;

determining, based on the predicted compression force, a deformation predicted to occur as a result of a sintering process following deposition of all of the layers;
calculating a modified geometry for each slice, wherein the modified geometry compensates for the predicted deformation;
calculating a second geometry of the object from the collective of the modified geometries for each of the slices, the second geometry corresponding to a print geometry for the object; and
printing the object based on the second geometry.

11. The method of claim 10 , wherein the weight of material corresponds to weight of all material residing atop said slice.

12. The method of claim 11 , wherein the corresponding compression force is associated with the deformation.

13. The method of claim 10 , wherein the measure of stress is calculated based on a location of a center of gravity of slices located above the slice.

14. The method of claim 10 , wherein the calculating for each slice further comprises quantifying a predicted loss of dimensional stability in debinding, due to loading.

15. The method of claim 10 , wherein before the printing step, the method further comprises generating a correction model of the object.

16. The method of claim 15 , wherein the correction model defines the modified print geometry of the object.

17. The method of claim 10 , wherein the printing comprises extruding feedstock.

18. The method of claim 17 , wherein the feedstock is extruded at a temperature between 160-250 degrees Celsius.

Assignees

• Desktop Metal Inc

Inventors

• Chin Ricardo
• Gibson Michael A
• Reeves Blake Z
• Raghu Shashank Holenarasipura

Classifications

• G05B19/4099 Primary

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

• B22F10/80

  Data acquisition or data processing · CPC title

• B22F10/32

  of the atmosphere, e.g. composition or pressure in a building chamber · CPC title

• B22F10/14

  by jetting of binder onto a bed of metal powder · CPC title

• B22F1/10

  Metallic powder containing lubricating or binding agents; Metallic powder containing organic material · CPC title