Adept three-dimensional printing

Patent metadata

Field	Value
Publication number	US-2017129052-A1
Application number	US-201615339712-A
Country	US
Kind code	A1
Filing date	Oct 31, 2016
Priority date	Nov 6, 2015
Publication date	May 11, 2017
Grant date	—

Abstract

The present disclosure provides three-dimensional (3D) printing methods, apparatuses, systems, and non-transitory computer-readable medium. The disclosure delineates real time manipulation of three-dimensional printing to reduce deformation. The present disclosure further provides 3D object formed using the methods, apparatuses, and systems.

First claim

What is claimed is:

1 . A system for forming at least one three-dimensional object, comprising: (a) an energy beam that transforms at least a portion of a material bed to a transformed material; and (b) a controller comprising a control-model that is related to a requested three-dimensional object, which control-model is configured in the controller, which controller is operative coupled to the energy beam and is programmed to direct the energy beam to transform the at least a portion of the material bed to form the at least one three-dimensional object using the control-model.

2 . The system of claim 1 , wherein the control-model is adjusted in real time during the forming of the at least one three-dimensional object.

3 . The method of claim 2 , wherein real time is during a dwell time of the energy beam along a hatch line forming a melt pool.

4 . The method of claim 1 , wherein the parameter comprises a temperature, height, or power density.

5 . The system of claim 1 , wherein the at least one three-dimensional object is a plurality of three-dimensional objects.

6 . The system of claim 5 , wherein the plurality of three-dimensional objects is formed in the same material bed.

7 . The system of claim 5 , wherein the plurality of three-dimensional objects is formed in parallel.

8 . The system of claim 1 , wherein the controller comprises a closed loop or open loop control.

9 . The system of claim 1 , wherein the controller comprises a feedback or feed-forward control.

10 . The system of claim 1 , wherein the control-model comprises one or more free parameters that are optimized in real time during the forming of the at least one three-dimensional object.

11 . The system of claim 1 , wherein the controller comprises an internal-state-system that provides an estimate of an internal state of the forming of the at least one three-dimensional object.

12 . The system of claim 11 , wherein the internal state is derived from one or more measurements comprising a measurement of the control variable or a measurement of the input parameters.

13 . The system of claim 11 , wherein the internal-state-system comprises a state-observer.

14 . The system of claim 1 , wherein the control-model comprises a state-observer-model.

15 . The system of claim 1 , wherein the controller comprises a graphical processing unit (GPU), system-on-chip (SOC), application specific integrated circuit (ASIC), application specific instruction-set processor (ASIPs), programmable logic device (PLD), or field programmable gate array (FPGA).

16 . The system of claim 1 , wherein the three-dimensional object is substantially similar to the requested three-dimensional object, wherein substantially is relative to the intended purpose of the three-dimensional object.

17 . A method for forming a three-dimensional object, comprising:
(a) transforming a portion of a material bed with an energy beam to form at least a portion of the three-dimensional object; and (b) controlling in real time at least one characteristics of the energy beam with a controller comprising a control-model related to a requested three-dimensional object, which control-model is configured in the controller, wherein the three-dimensional object is substantially similar to the requested three-dimensional object.

18 . The method of claim 17 , wherein the control-model is adjusted in real time during the forming of the three-dimensional object.

19 . The method of claim 17 , wherein real time is during a dwell time of the energy beam along a hatch line forming a melt pool.

20 . The method of claim 17 , wherein the controlling uses a processor comprising at least 3 Tera floating point operations per second, according to a benchmark.

21 . The method of claim 17 , further comprising adjusting the at least one characteristics of the energy beam and repeating (a) to (b).

22 . The method of claim 17 , wherein the closed loop control uses at least one threshold value.

23 . The method of claim 17 , wherein the control-model comprises a simplified model relative to the requested model of the three-dimensional object.

24 . The method of claim 17 , wherein substantially is relative to the intended purpose of the three-dimensional object.

25 . The method of claim 17 , wherein the control-model comprises a state-observer-model.

26 . The method of claim 17 , wherein the control-model comprises a simulation.

27 . The method of claim 26 , wherein the simulation comprises a temperature or mechanical simulation of the three-dimensional printing.

28 . The method of claim 26 , wherein the simulation comprises a material property of the three-dimensional object.

29 . The method of claim 26 , wherein the simulation comprises a geometry of the three-dimensional object.

30 . The method of claim 26 , wherein the control-model is dynamically adjusted in the real time during the forming of the three-dimensional object.

Assignees

• Velo3D Inc

Inventors

• Buller Benyamin
• LAPPAS Tasso
• Mendelsberg Rueben
• Korepanov Sergey

Classifications

• B29C64/268

  using laser beams; using electron beams [EB] · CPC title

• G06F30/00

  Computer-aided design [CAD] · CPC title

• B22F12/41

  characterised by the type, e.g. laser or electron beam · CPC title

• B22F12/49

  Scanners · CPC title

• B22F10/38

  to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures · CPC title