Custom three-dimensional (3D) print mode generation

Patent metadata

Field	Value
Publication number	US-11969949-B2
Application number	US-201917420074-A
Country	US
Kind code	B2
Filing date	Jan 10, 2019
Priority date	Jan 10, 2019
Publication date	Apr 30, 2024
Grant date	Apr 30, 2024

Abstract

A method of custom print mode generation in a three-dimensional (3D) printing device may include printing a plurality of parts with a plurality of 3D printing devices, the parts each being printed using different process parameters, and capturing a plurality of images of the parts. The method may also include, with an image analysis module, analyzing the images to classify the parts into a plurality of defect gradings, and adjusting a number of the process parameters based on characteristics of the parts identified by a user as undesirable. The examiner may also include, with a recommending module, creating a custom print mode based on the parts defect gradings and adjusted process parameters.

First claim

What is claimed is:

1. A method of custom print mode generation in a three-dimensional (3D) printing device, comprising:
printing a plurality of parts with a plurality of 3D printing devices, the parts each being printed using different process parameters;
capturing a plurality of images of the parts;
with an image analysis module, analyzing the images to classify the parts into a plurality of defect gradings;
adjusting a number of the process parameters based on characteristics of the parts identified by a user as undesirable;
with a recommending module, creating a custom print mode based on the parts defect gradings and adjusted process parameters.

2. The method of claim 1 , wherein the parts comprise at least one user-defined part and at least one reference part.

3. The method of claim 1 , wherein capturing the plurality of images of the parts comprises, rearranging the parts with a robotic arm, rearranging the parts using a shaking mechanism, capturing the parts in a plurality of lighting conditions, capturing the parts in a plurality of wavelengths of light, or combinations thereof.

4. The method of claim 1 , wherein the process parameters comprise fusing lamp power levels, fusing lamp scan speeds, warming lamp power levels, warming lamp scan speeds, powder temperatures, humidity levels, powder dose volumes, spreader roller rotation velocities, spreader roller transverse velocities, fusing agent density levels, cooling agent density levels, build material melting points, build material crystallization temperatures, build material conductivity, build material thermal mass values, build material thermal properties, build material densities, build material flowability, build material friction properties, build material mechanical properties, part model used, a number of layers assigned to a core of the part model used, a number of layers assigned to a mantle of the part model used, a number of layers assigned to a shell of the part model used, part post processing methods used, percentage of part expansion of an original geometry of the part, percentage of part dilation of the original geometry of the part, or combinations thereof.

5. The method of claim 1 , wherein creating the custom print mode based on the adjusted process parameters comprises performing a plurality of iterations of printing the plurality of parts with the plurality of 3D printing devices, each iteration comprising different process parameters.

6. The method of claim 1 , wherein capturing the plurality of images of the parts comprises capturing the images in a visible electromagnetic spectrum, an infrared electromagnetic spectrum, an ultraviolet electromagnetic spectrum, a 3D imaging device, or combinations thereof.

7. The method of claim 1 , wherein creating the custom print mode based on the parts defect gradings and adjusted process parameters comprises, with the recommending module, calculating a nominal logistic regression to predict a likelihood of obtaining different defect types using different process parameters.

8. A non-transitory computer readable medium comprising computer usable program code embodied therewith, the computer usable program code to, when executed by a processor:
present a plurality of settings defining a plurality of optimizable process parameters;
present an indication of part quality for a selection of at least one of the settings for a part to be printed using a 3D printing device, wherein the indication of part quality is based on previously classified part defect gradings; and
adjust a number of the process parameters based on characteristics of the parts identified by a user as undesirable.

9. The computer readable medium of claim 8 , comprising:
computer usable program code to, when executed by the processor:
capture a plurality of images of a plurality of parts printed using a 3D printing device, the parts each being printed using different process parameters executing a design of experiments (DoE) process;
with an image analysis module, analyze the images to classify the parts into the part defect gradings;
adjust a number of the process parameters based on characteristics of the parts; and
with a recommending module, create a custom print mode based on the part defect gradings and adjusted process parameters;
wherein the DoE process comprises:
varying the process parameters of each of the builds of each part; and
evaluating an impact of the process parameters and the interactions of the process parameters on the parts.

10. The computer readable medium of claim 9 , wherein capturing the plurality of images of the parts comprises, rearranging the parts with a robotic arm, rearranging the parts using a shaking mechanism, capturing the parts in a plurality of lighting conditions, capturing the parts in a plurality of wavelengths of light, capturing the images in a visible electromagnetic spectrum, capturing the images in an infrared electromagnetic spectrum, capturing the images in an ultraviolet electromagnetic spectrum, or combinations thereof.

11. The computer readable medium of claim 9 , wherein the process parameters comprise fusing lamp power levels, fusing lamp scan speeds, warming lamp power levels, warming lamp scan speeds, powder temperatures, humidity levels, powder dose volumes, spreader roller rotation velocities, spreader roller transverse velocities, fusing agent density levels, cooling agent density levels, build material melting points, build material crystallization temperatures, build material conductivity, build material thermal mass values, build material thermal properties, build material densities, build material flowability, build material friction properties, build material mechanical properties, or combinations thereof.

12. The computer readable medium of claim 8 , wherein the previously classified defect gradings are a product of an analysis performed using a neural network.

13. The computer readable medium of claim 9 , wherein creating the custom print mode based on the parts defect gradings and adjusted process parameters comprises, with the recommending module, calculating a nominal logistic regression to predict a likelihood of obtaining different defect types using different process parameters.

14. A system for generating custom three-dimensional (3D) print modes, comprising:
a design of experiments (DoE) module to instruct at least one 3D printing device to print a plurality of parts, the parts each being printed using different process parameters, wherein the DoE module:
varies the process parameters of each of the builds of each part; and
evaluates an impact of the process parameters and the interactions of the process parameters on the parts;

an imaging device to capture a plurality of images of the plurality of parts;
an image analysis module to classify the parts into a plurality of defect gradings;
an adjustment module to adjust a number of the process parameters based on characteristics of the parts identified by a user as undesirable; and
a recommending module to create a custom print mode based on the parts defect gradings and adjusted process parameters.

15. The system of claim 14 , comprising a part reorientation device to reorient the parts, wherein the part reorientation device comprises a robotic arm, a shaking mechanism, or combinations thereof.

Assignees

• Hewlett Packard Development Co

Inventors

• Kothari Sunil
• Ronk Kelly
• Powell Anthony
• Zeng Jun
• Khan Md Abdullah Al Hafiz
• Heiles Tod
• Obegi Goffril

Classifications

• B29C64/393 Primary

  for controlling or regulating additive manufacturing processes · CPC title

• B29C64/379

  Handling of additively manufactured objects, e.g. using robots · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• G06T7/0004

  Industrial image inspection · CPC title