Systems and methods for adjusting a three-dimensional (3D) model during additive manufacturing

Patent metadata

Field	Value
Publication number	US-11597153-B1
Application number	US-201916453691-A
Country	US
Kind code	B1
Filing date	Jun 26, 2019
Priority date	Jun 26, 2018
Publication date	Mar 7, 2023
Grant date	Mar 7, 2023

Abstract

Embodiments of the present disclosure are drawn to systems and methods for adjusting a three-dimensional (3D) model used in metal additive manufacturing to maintain dimensional accuracy and repeatability of a fabricated 3D part. These embodiments may be used to reduce or remove geometric distortions in the fabricated 3D part. One exemplary method may include: receiving, via one or more processors, a selection made by a user; receiving a 3D model of a desired part; retrieving at least one model constant based on the user's selection; receiving an input of at least one process variable setting from a set of process variable settings; generating transformation factors based on the at least one process variable parameter and the at least one model constant; transforming the 3D model of the desired part based on the transformation factors; and generating processing instructions for fabricating the transformed 3D model of the desired part.

First claim

We claim:

1. A method for maintaining dimensional accuracy of a fabricated three-dimensional (3D) part by adjusting a 3D model used in metal additive manufacturing, comprising:
receiving, using a processor, a selection for fabricating a desired 3D part;
receiving a 3D model of the desired 3D part;
retrieving at least one model constant based on the selection;
receiving an input of at least one process variable parameter from a set of process variable parameters, wherein the at least one process variable parameter includes an offset based on a level of binder saturation to accommodate for binder bleeding;
transforming the 3D model of the desired 3D part based on the process variable parameters; and
generating processing instructions for fabricating the transformed 3D model of the desired 3D part; and
additively manufacturing the desired 3D part via binder jetting additive manufacturing.

2. A method for maintaining dimensional accuracy of a fabricated three-dimensional (3D) part by adjusting a 3D model used in metal additive manufacturing, comprising:
receiving, using a processor, a selection for fabricating a desired 3D part;
receiving a 3D model of the desired 3D part;
receiving an input of at least one process variable parameter from a set of process variable parameters;
retrieving at least one model and at least one associated model constant based on the selection;
generating transformation factors based on the at least one process variable parameter and the at least one model constant;
transforming the 3D model of the desired 3D part based on the transformation factors wherein the transformation includes at least one of an offsetting operation, a rotation operation and a stretching operation; and
generating processing instructions for fabricating the transformed 3D model of the desired 3D part; and
additively manufacturing the desired 3D part via binder jetting additive manufacturing.

3. A system for adjusting a three-dimensional (3D) model used in metal additive manufacturing, comprising:
a processor configured to:
receive, using a processor, a selection for fabricating a desired 3D part;
receive a 3D model of the desired 3D part;
retrieve at least one model constant based on the selection;
receive an input of at least one process variable parameter from a set of process variable parameters, wherein the at least one process variable parameter includes an offset based on a level of binder saturation to accommodate for binder bleeding;
generate transformation factors based on the at least one process variable parameter and the at least one model constant;
transform the 3D model of the desired 3D part based on the transformation factors; and
generate processing instructions for fabricating the transformed 3D model of the desired 3D part, wherein the 3D part is to be manufactured via binder jetting additive manufacturing.

4. A non-transitory computer-readable medium storing instructions, the instructions, when executed by a computer system, cause the computer system to perform a method, the method comprising:
receiving, using a processor, a selection for fabricating a desired 3D part;
receiving a 3D model of the desired 3D part;
retrieving at least one model constant based on the selection;
receiving an input of at least one process variable parameter from a set of process variable parameters, wherein the at least one process variable parameter includes an offset based on a level of binder saturation to accommodate for binder bleeding;
generating transformation factors based on the at least one process variable parameter and the at least one model constant;
transforming the 3D model of the desired 3D part based on the transformation factors; and
generating processing instructions for fabricating the transformed 3D model of the desired 3D part, wherein the 3D part is to be manufactured via binder jetting additive manufacturing.

Assignees

• Desktop Metal Inc

Inventors

• Barbati Alexander C
• Gibson Michael Andrew
• Hudelson George
• Mykulowycz Nicholas Mark
• Kernan Brian D
• Tuncer Nihan

Classifications

• B33Y50/00

  Data acquisition or data processing for additive manufacturing · CPC title

• B29C64/386

  Data acquisition or data processing for additive manufacturing · CPC title

• B29C64/165

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y50/02 Primary

  for controlling or regulating additive manufacturing processes · CPC title