Identifying passes of additive manufacturing processes depicted in thermal images

Patent metadata

Field	Value
Publication number	US-11511534-B2
Application number	US-201816606767-A
Country	US
Kind code	B2
Filing date	Mar 19, 2018
Priority date	Mar 19, 2018
Publication date	Nov 29, 2022
Grant date	Nov 29, 2022

Abstract

In an example, an apparatus includes an image processing system, a print engine, and a vision system. The image processing system generates electronic signals based on a model of an object to be fabricated using an additive manufacturing process. The print engine performs the additive manufacturing process in a plurality of passes based on the electronic signals. The vision system acquires a plurality of thermal images of the plurality of passes and assigns individual passes to individual images based on data acquired during a build of a calibration object by the additive manufacturing process. The print engine may further include a material coater to spread a powder coating material, a plurality of fluid ejection devices to eject a fusing agent, and an emitter to emit energy to fuse the fusing agent and the powder coating material into a layer of the object to be fabricated.

First claim

What is claimed is:

1. An apparatus, comprising:
an image processing system to generate electronic signals based on a model of an object to be fabricated using an additive manufacturing process;
a print engine to perform the additive manufacturing process in a plurality of passes based on the electronic signals, wherein the print engine comprises:
a material coater to spread a powder coating material;
a plurality of fluid ejection devices to eject a fusing agent; and
an emitter to emit energy to fuse the fusing agent and the powder coating material into a layer of the object to be fabricated; and

a vision system to acquire a plurality of thermal images of the plurality of passes and to assign individual passes of the plurality of passes to individual images of the plurality of thermal images based on data acquired during a build of a calibration object by the additive manufacturing process.

2. The apparatus of claim 1 , wherein the data acquired during the build of the calibration object comprises temperature ranges present during the build of the calibration object.

3. The apparatus of claim 2 , wherein the data acquired during the build of the calibration object further comprises a movement pattern of the plurality of fluid ejection devices and a movement pattern of the material coater.

4. The apparatus of claim 3 , wherein the movement pattern of the plurality of fluid ejection devices occurs in a first region of interest of the build bed.

5. The apparatus of claim 4 , wherein the movement pattern of the plurality of fluid ejection devices indicates a direction in which the plurality of fluid ejection devices is moving in an individual image of the plurality of thermal images.

6. The apparatus of claim 4 , wherein the first region of interest comprises an area around a periphery of the build bed.

7. The apparatus of claim 2 , wherein the temperature ranges present during the build of the calibration object are measured in a build bed of the additive manufacturing system.

8. The apparatus of claim 7 , wherein the temperature ranges present during the build of the calibration object include
a median value of a temperature in a first region of interest of the build bed, wherein the median value is identified according to an individual image of the plurality of thermal images, and wherein the vision system assigns an individual
pass of the plurality of passes to the individual image of the plurality of thermal images based on a first temperature range of the temperature ranges that was present in a pass of a plurality of passes made during the build of the calibration object.

9. The apparatus of claim 8 , wherein the first region of interest is selected based on knowledge of occlusions that are likely to be present in the plurality of thermal images, and wherein the knowledge is based on occlusions that are present in a plurality of thermal images acquired during plurality of passes made during the build of the calibration object.

10. The apparatus of claim 8 , wherein the first region of interest is selected by scanning the build bed of the additive manufacturing system on a predefined set of regions of interest until multiple occurrences of temperature differences that at least meet a threshold temperature difference are detected.

11. The apparatus of claim 1 , wherein the object to be fabricated and the calibration object are built using a same powder coating material and recipe.

12. The apparatus of claim 1 , wherein the object to be fabricated is one of a plurality of identical objects that is to be fabricated during the plurality of passes.

Assignees

• Hewlett Packard Development Co

Inventors

• Kothari Sunil
• Catana Juan Carlos
• Heiles Tod
• Zeng Jun
• Dispoto Gary J

Classifications

• B22F12/90

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

• B22F12/67

  Blades · CPC title

• B22F12/47

  parallel to the deposition plane · CPC title

• B22F10/85

  for controlling or regulating additive manufacturing processes · CPC title

• B22F10/368

  Temperature or temperature gradient, e.g. temperature of the melt pool · CPC title