System and method for the additive manufacture of components

Patent metadata

Field	Value
Publication number	US-12427723-B2
Application number	US-202117375369-A
Country	US
Kind code	B2
Filing date	Jul 14, 2021
Priority date	Jul 14, 2020
Publication date	Sep 30, 2025
Grant date	Sep 30, 2025

Abstract

A system includes at least one electronic controller configured to generate machine code based on a predetermined component geometry associated with a component and at least one printing device. The system includes a comparison system comprising at least one recording device configured to record a geometry of the component using one of a strip projection routine and a white-light interferometry routine and at least one comparison controller configured to compare the geometry of the component with the predetermined component geometry. When a deviation exceeds a predetermined limit value, the at least one comparison controller is configured to generate modification information and deliver the modification information to the at least one electronic controller. The at least one electronic controller is configured to modify the machine code based on the modification information and to deliver the modified machine code to the printing device.

First claim

What is claimed is:

1. A system for additively manufacturing a component, the system comprising:
at least one electronic controller configured to generate machine code for the component based on a predetermined component geometry associated with the component;
at least one printing device configured to perform an additive manufacturing routine associated with a partial manufacturing of the component based on the machine code; and
a comparison system comprising at least one recording device and at least one comparison controller, wherein the at least one recording device is configured to record a geometry of the partially manufactured component using a strip projection routine, wherein the at least one comparison controller is configured to compare the recorded geometry of the partially manufactured component to the predetermined component geometry by comparing a magnitude of a position vector with a magnitude of a value corresponding to the recorded geometry of the partially manufactured component,
wherein, in response to a deviation of the recorded geometry of the partially manufactured component from the predetermined component geometry exceeding a predetermined limit value, the at least one comparison controller is configured to generate modification information and deliver the modification information to the at least one electronic controller, wherein the predetermined limit value is the magnitude of the position vector of a spatial point of a theoretical envelope around a predetermined component geometry,
wherein the at least one electronic controller is further configured to modify the machine code based on the modification information and to deliver the modified machine code to the printing device, and
wherein the at least one printing device is further configured to complete the partially manufactured component based on the modification of the machine code.

2. The system according to claim 1 , wherein the at least one comparison controller is configured to generate the modification information when the geometry of the component deviates from the predetermined component geometry by a value that is within a range of 0.1% to 10%.

3. The system according to claim 1 , wherein the predetermined limit value is one of a theoretical envelope around the predetermined component geometry and a spatial point of the theoretical envelope.

4. The system according to claim 1 , wherein the predetermined component geometry is one of a standard tessellation language (STL) data model of the component and a slice model of the component.

5. The system according to claim 1 , wherein the printing device comprises a printing head, and wherein:
the at least one electronic controller is configured to modify the machine code such that the printing head is moved with an offset when the modified machine code is executed by the printing device;
the at least one electronic controller is configured to vary at least one of a width of material tracks and a number of material tracks when the modified machine code is executed by the printing device; and
the at least one electronic controller is configured to decompose at least one layer of the predetermined component geometry into theoretical slices based on a geometrical error recorded by the recording device.

6. The system according to claim 1 , wherein the at least one recording device is further configured to record the geometry of the component using a white-light interferometry routine.

7. The system of claim 1 , wherein the at least one electronic controller is further configured to:
generate a track based on the predetermined component geometry, wherein the predetermined component geometry is decomposed into theoretical slices, layers, levels, or a combination thereof.

8. A method for additively manufacturing a component, the method comprising:
generating machine code for the component based on a predetermined component geometry associated with the component, wherein the predetermined component geometry is decomposed into theoretical slices, layers, levels, or a combination thereof;
creating, via an additive manufacturing routine, a partial manufacturing of the component based on the machine code;
recording a geometry of the partially manufactured component using a strip projection routine;
comparing the recorded geometry of the partially manufactured component to the predetermined component geometry by comparing a magnitude of a position vector with a magnitude of a value corresponding to the recorded geometry of the partially manufactured component;
generating modification information in response to a deviation of the recorded geometry of the partially manufactured component from the predetermined component geometry exceeding a predetermined limit value, wherein the predetermined limit value is the magnitude of the position vector of a spatial point of a theoretical envelope around a predetermined component geometry; and
modifying the machine code based on the modification information, wherein the partially manufactured component is completed based on the modification of the machine code.

9. The method according to claim 8 , wherein the modification information is generated when the geometry of the component deviates from the predetermined component geometry by a value that is within a range of 0.1% to 10%.

10. The method according to claim 8 , wherein the predetermined limit value is one of a theoretical envelope around the predetermined component geometry and a spatial point of the theoretical envelope.

11. The method according to claim 8 , wherein the predetermined component geometry is one of a standard tessellation language (STL) data model of the component and a slice model of the component.

12. The method according to claim 8 further comprising:
modifying the machine code such that a printing head is moved with an offset when the modified machine code is executed by a printing device comprising the printing head;
varying at least one of a width of material tracks and a number of material tracks when the modified machine code is executed by the printing device; and
decomposing at least one layer of the predetermined component geometry into theoretical slices based on a geometrical error recorded by a recording device.

13. The method according to claim 8 , wherein the recordation of the geometry of the component further uses a white-light interferometry routine.

14. The method of claim 8 , further comprising:
generating a track based on the predetermined component geometry.

15. A system for additively manufacturing a component, the system comprising:
at least one electronic controller configured to generate machine code for the component based on a predetermined component geometry associated with the component;
at least one printing device configured to perform an additive manufacturing routine associated with a partial manufacturing of the component based on the machine code; and
a comparison system comprising at least one recording device and at least one comparison controller, wherein the at least one recording device is configured to record a geometry of the partially manufactured component using a strip projection routine, wherein the at least one comparison controller is configured to compare the recorded geometry of the partially manufactured component to the predetermined component geometry by comparing a magnitude of a position vector with a magnitude of a value corresponding to the recorded geometry of the partially manufactured component,
wherein:
when the component is in at least a partially manufactured state and in response to a deviation of the

Assignees

• Ford Global Tech Llc

Inventors

• Baranowski Thomas
• Broda Maik
• Franzen Markus
• Rebmann Pascal

Classifications

• G06T7/001

  using an image reference approach · CPC title

• B33Y30/00

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

• G06T7/60

  Analysis of geometric attributes · CPC title

• G06T2207/30164

  Workpiece; Machine component · CPC title

• B33Y50/02 Primary

  for controlling or regulating additive manufacturing processes · CPC title