Adaptive 3D printing

Patent metadata

Field	Value
Publication number	US-11718037-B2
Application number	US-202117224676-A
Country	US
Kind code	B2
Filing date	Apr 7, 2021
Priority date	Apr 21, 2017
Publication date	Aug 8, 2023
Grant date	Aug 8, 2023

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 configuring an additive manufacturing system, comprising:
dividing an initial model into a plurality of segments, the initial model defining a geometry of an object;
calculating, for each of the plurality of segments, a stress value using a cross-sectional area of the segment and a calculated weight of material residing atop the segment;
predicting a deformation of each of the segments according to the associated stress value as a result of a sintering process following deposition of all of the segments;
calculating, for each of the plurality of segments, a modified geometry of the segment as a function of the predicted deformation;
defining a printed geometry of the object from the collective of modified geometries of each of the segments; and
printing the object according to the printed geometry.

2. The method of claim 1 , wherein the stress value is calculated as a function of a location of a center of gravity of segments located above the segment.

3. The method of claim 1 , wherein the predicted deformation is based on a predicted anisotropic distortion due to anisotropy in a material composition of the object in the printed state.

4. The method of claim 1 , wherein the predicted deformation is based on a predicted gravitational force on the object during a sintering process.

5. The method of claim 1 , wherein the predicted deformation is based on a predicted deformation caused by at least one artifact exhibited by print patterns of a printed object.

6. The method of claim 1 , wherein the predicted deformation is based on a predicted deformation of the segment based on a predicted gravitational force on the object.

7. The method of claim 1 , wherein the predicted deformation is based on a predicted difference between shrinkage of an outer layer of the object and shrinkage of an interior of the object during a sintering process.

8. The method of claim 1 , further comprising calculating a modified geometry of a support structure as a function of the predicted deformation, the support structure being printed concurrently with the object and being positioned beneath at least a portion of the object.

9. A method of manufacturing an object, comprising:
dividing an initial model into a plurality of segments, the initial model defining a geometry of an object;
calculating, for each of the plurality of segments, a stress value using a cross-sectional area of the segment and a calculated weight of material residing atop the segment;
calculating, for each of the plurality of segments, a predicted deformation of the segment according to the associated stress value as a result of a post-processing;
calculating, for each of the plurality of segments, a modified geometry of the segment as a function of the predicted deformation, the modified geometry compensating for the predicted deformation of corresponding portions of the printed object; and
updating print parameters of the object to incorporate the modified geometry, the print parameters defining a printed geometry of the object;
printing a part according to the updated print parameters; and
sintering the part, the sintering causing the part to transform toward a geometry corresponding to the geometry of the object.

Assignees

• Desktop Metal Inc

Inventors

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

Classifications

• B29C64/386 Primary

  Data acquisition or data processing for additive manufacturing · CPC title

• B22F1/10

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

• B22F3/24

  After-treatment of workpieces or articles {(B22F3/1146 takes precedence)} · CPC title

• B22F10/00

  Additive manufacturing of workpieces or articles from metallic powder (apparatus or devices therefor B22F12/00) · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title