Methods for post-processing additively manufactured objects with sensor feedback

Patent metadata

Field	Value
Publication number	US-12240176-B2
Application number	US-202218050804-A
Country	US
Kind code	B2
Filing date	Oct 28, 2022
Priority date	Oct 28, 2021
Publication date	Mar 4, 2025
Grant date	Mar 4, 2025

Abstract

Systems, methods, and devices for post-processing additively manufactured objects are disclosed herein. In some embodiments, a method includes receiving a plurality of additively manufactured objects having excess material thereon. The method can include removing the excess material from the plurality of additively manufactured objects by rotating the plurality of additively manufactured objects. The method can also include receiving sensor data indicative of a cleaning status of the plurality of additively manufactured objects. The method can further include adjusting, based on the sensor data, an operational parameter that enhances removal of the excess material from the plurality of additively manufactured objects.

First claim

We claim:

1. A method comprising:
receiving a plurality of additively manufactured objects on a rotor, the plurality of additively manufactured objects having excess material thereon;
removing the excess material from the plurality of additively manufactured objects by rotating the plurality of additively manufactured objects using the rotor;
receiving sensor data indicative of a cleaning status of the plurality of additively manufactured objects while the plurality of additively manufactured objects remain on the rotor; and
adjusting, based on the sensor data, an operational parameter of the rotor that enhances removal of the excess material from the plurality of additively manufactured objects.

2. The method of claim 1 , wherein the plurality of additively manufactured objects comprise a partially cured polymeric resin, and the excess material comprises uncured polymeric resin.

3. The method of claim 2 , wherein the uncured polymeric resin has a viscosity of at least 15 Pa-s at 20° C.

4. The method of claim 1 , wherein the sensor data is generated by one or more of the following: an optical sensor, a force sensor, a weight sensor, an ultrasonic sensor, a temperature sensor, a radiation sensor, or a chemical sensor.

5. The method of claim 1 , wherein the sensor data is indicative of an amount of the excess material removed from the plurality of additively manufactured objects.

6. The method of claim 1 , wherein the sensor data is indicative of an amount of the excess material remaining on the plurality of additively manufactured objects.

7. The method of claim 1 , wherein the sensor data comprises image data of the plurality of additively manufactured objects.

8. The method of claim 7 , further comprising comparing the image data to reference image data to determine the cleaning status of the plurality of additively manufactured objects.

9. The method of claim 1 , further comprising collecting at least some of the excess material removed from the plurality of additively manufactured objects.

10. The method of claim 9 , wherein the sensor data comprises a measurement of an amount of the collected excess material.

11. The method of claim 9 , further comprising reusing the collected excess material in a subsequent additive manufacturing process.

12. The method of claim 1 , wherein the operational parameter comprises one or more of the following: a rotation speed of the rotor, a rotation direction of the rotor, a rotation duration of the rotor, or a number of rotation cycles of the rotor.

13. The method of claim 1 , wherein the rotor comprises a plurality of adjustable mounting structures, each adjustable mounting structure supporting a subset of the additively manufactured objects, and the operational parameter comprises a position of the adjustable mounting structure.

14. The method of claim 1 , further comprising adjusting an environmental temperature based on the sensor data.

15. The method of claim 1 , further comprising applying energy to the plurality of additively manufactured objects to cure at least a portion thereof.

16. The method of claim 15 , further comprising:
receiving second sensor data indicative of a curing status of the plurality of additively manufactured objects; and
adjusting, based on the second sensor data, a second operational parameter that enhances curing of the plurality of additively manufactured objects.

17. The method of claim 16 , wherein the second operational parameter comprises one or more of the following: a rotation speed of the rotor, a rotation direction of the rotor, a rotation duration of the rotor, a number of rotation cycles of the rotor, an environmental temperature, or an energy output of an energy source.

18. The method of claim 1 , wherein the plurality of additively manufactured objects are rotated around two or more axes of rotation.

19. The method of claim 1 , further comprising applying a material to the plurality of additively manufactured objects.

20. The method of claim 1 , further comprising transferring the plurality of additively manufactured objects to another location for additional processing.

21. The method of claim 1 , wherein the plurality of additively manufactured objects are produced by a stereolithography process.

22. The method of claim 1 , wherein the plurality of additively manufactured objects comprise a plurality of orthodontic appliances.

23. The method of claim 22 , wherein the plurality of orthodontic appliances are configured to reposition a patient's teeth from an initial arrangement toward a target arrangement.

24. The method of claim 23 , wherein the plurality of orthodontic appliances are manufactured based on a digital treatment plan representing a series of tooth arrangements for repositioning the patient's teeth from the initial arrangement toward the target arrangement.

Assignees

• Align Technology Inc

Inventors

• Meenakshisundaram Viswanath
• Kaza Srinivas
• Li Chunhua
• Pickens Lance Robert
• Stromenger Shawn
• Sato Jun
• O'Leary Siobhan
• Webber Peter
• Kelly Brett E
• Chavez Jennifer

Classifications

• B29C71/04

  by wave energy or particle radiation {, e.g. for curing or vulcanising preformed articles (during moulding, e.g. in a mould B29C35/08)} · CPC title

• B29C35/0805

  using electromagnetic radiation · CPC title

• B29C64/30

  Auxiliary operations or equipment · CPC title

• B29C64/357

  Recycling · CPC title

• B29C64/124

  using layers of liquid which are selectively solidified · CPC title