Printed object correction via computer vision

Patent metadata

Field	Value
Publication number	US-2018297114-A1
Application number	US-201715487944-A
Country	US
Kind code	A1
Filing date	Apr 14, 2017
Priority date	Apr 14, 2017
Publication date	Oct 18, 2018
Grant date	—

Abstract

A camera assembly is employed in additive manufacturing to improve the fidelity of a printed object. The camera may scan the surface of a build plate of a 3D printer and an object as it is being printed to generate image data. The image data is processed to detect errors in the build plate or printed object. The printer compensates for the detected errors, which can including modifying the printer configuration and/or modifying the instructions for printing a given object. Using the updated configuration, subsequent objects may then be printed, under a corrected process, to produce an object with fidelity to an original object model.

First claim

What is claimed is:

1 . A method of printing an object, comprising:
printing a first object at a 3D printer based on an initial model of an object; scanning a plurality of layers of the first object concurrently with the printing to generate image data of the first object; detecting deviations between the image data and the initial model; updating print parameters of the object based on an initial model of the object and the image data, the print parameters defining printed geometry of the object with modifications to the initial model based on the detected deviations; and printing a second object based on the print parameters.

2 . The method of claim 1 , wherein the scanning includes capturing at least one photograph of the object via a camera coupled to a printer head.

3 . The method of claim 2 , wherein the at least one photograph includes a plurality of photographs, and further comprising stitching together the plurality of photographs to generate the image of the object.

4 . The method of claim 3 , further comprising:
moving the camera and printer head through a plurality of distinct locations above the build plate; and capturing each of the plurality of photographs at a respective one of the plurality of locations.

5 . The method of claim 1 , wherein the scanning includes capturing photographs of a plurality of cross-sectional layers of the first object concurrently with the printing of the first object, the image data incorporating the photographs.

6 . The method of claim 5 , wherein updating the print parameters includes modifying the geometry of a representation of the object based on deviations between the initial model and the photographs of the plurality of cross-sectional layers of the first object.

7 . The method of claim 1 , wherein updating the print parameters includes generating a correction tool path for a print head based on the detected deviations.

8 . The method of claim 7 , wherein printing the second object includes controlling the print head to print the second object based on the correction tool path.

9 . The method of claim 7 , wherein printing the second object includes controlling material deposition flow rate based on the correction tool path.

10 . The method of claim 7 , wherein printing the first object includes:
printing an initial portion of the first object according to an initial tool path; and printing a successive portion of the first object according to the correction tool path.

11 . The method of claim 1 , wherein updating print parameters includes generating a correction model of the object, the correction model defining the printed geometry of the object with modifications to the initial model based on the detected deviations.

12 . A system for printing objects, comprising:
a build chamber; a printer head configured to print objects within the build chamber; a camera mounted to the printer head and configured to capture images within the build chamber; and a controller configured to 1) control the camera to scan a plurality of layers of a first object concurrently with printing of the first object to generate image data of the first object, 2) detecting deviations between the image data and an initial model of the object, and 3) update print parameters of the object based on an initial model of the object and the image data, the print parameters defining printed geometry of the object with modifications to the initial model based on the detected deviations.

13 . The system of claim 12 , wherein the scan includes capturing at least one photograph of the object via the camera.

14 . The system of claim 13 , wherein the at least one photograph includes a plurality of photographs, and wherein the control further comprising stitching together the plurality of photographs to generate the image of the object.

15 . The system of claim 14 , wherein the controller is further configured to move the camera and printer head through a plurality of distinct locations above the build plate and capture each of the plurality of photographs at a respective one of the plurality of locations.

16 . The system of claim 12 , wherein the controller is further configured to capture photographs of a plurality of cross-sectional layers of the first object concurrently with the printing of the first object, the image data incorporating the photographs.

17 . The system of claim 16 , wherein the controller updates the print parameters to include modified geometry of the first object based on deviations between the initial model and the photographs of the plurality of cross-sectional layers of the first object.

18 . The system of claim 12 , wherein the controller updates the print parameters to include a correction tool path for a print head based on the detected deviations.

19 . The system of claim 12 , wherein the controller updates the print parameters to include a correction model of the object, the correction model defining the printed geometry of the object with modifications to the initial model based on the detected deviations.

20 . A method of printing an object, comprising:
printing an initial portion of an object at a 3D printer based on an initial model of an object; scanning a plurality of layers of the first object concurrently with the printing to generate image data of the first object; detecting deviations between the image data and the initial model; updating print parameters of the object based on an initial model of the object and the image data, the print parameters defining printed geometry of the object with modifications to the initial model based on the detected deviations; and printing a successive portion of the object based on the print parameters.

Assignees

• Desktop Metal Inc

Inventors

• Preston Aaron
• Mykulowycz Nicholas

Classifications

• B22F3/22 Primary

  for producing castings from a slip · CPC title

• B22F10/43

  characterised by material · CPC title

• B22F10/16

  by embedding the binder within the powder bed · CPC title

• B22F10/31

  Calibration of process steps or apparatus settings, e.g. before or during manufacturing · CPC title

• B22F10/30

  Process control · CPC title