Build layer coverage analysis

Patent metadata

Field	Value
Publication number	US-2019022950-A1
Application number	US-201616069509-A
Country	US
Kind code	A1
Filing date	Mar 10, 2016
Priority date	Mar 10, 2016
Publication date	Jan 24, 2019
Grant date	—

Abstract

Examples include apparatuses, processes, and methods for generating three-dimensional objects. An example apparatus comprises build material distributor and a controller. Examples distribute a particular build layer in a build area of the apparatus over a previous build layer. Examples determine a build layer temperature corresponding to the particular build layer. Examples analyze build layer coverage for the particular build layer based at least in part on a build layer temperature of the previous build layer and the build layer temperature of the particular build layer. Examples selectively recoat the particular build layer with additional build material based at least in part on the build layer coverage for the particular build layer.

First claim

1 . An apparatus for generating a three-dimensional object, the apparatus comprising:
a build material distributor to distribute respective build layers of build material in a build area of the apparatus; and a controller to:
control the build material distributor to distribute a particular build layer in the build area over a previous build layer;
determine a build layer temperature corresponding to the particular build layer;
analyze build layer coverage for the particular build layer based at least in part on a build layer temperature of the previous build layer and the build layer temperature of the particular build layer; and
control the build material distributor to selectively recoat the particular build layer with additional build material based at least in part on the build layer coverage for the particular build layer.

2 . The apparatus of claim 1 , further comprising:
at least one build layer temperature sensor, wherein the controller determines the build layer temperature of the particular build layer with the at least one temperature sensor.

3 . The apparatus of claim 1 , wherein the controller to control the build material distributor to selectively recoat the particular build layer with additional build material comprises the controller to control the build material distributor to recoat the particular build layer with additional build material in response to determining that the build layer coverage for the particular build layer is insufficient.

4 . The apparatus of claim 1 , further comprising:
an agent distributor to selectively distribute agent in the build area; and at least one energy source, wherein the controller is further to:
control the agent distributor to selectively distribute agent on the particular build layer in response to determining that build layer coverage for the particular layer is sufficient; and
control the at least one energy source to apply energy to the particular build layer after selective distribution of the agent on the particular build layer.

5 . The apparatus of claim 1 , wherein the controller to analyze build layer coverage for the particular build layer comprises the controller to:
detect temperature edges for locations of the particular build layer based at least in part on the build layer temperature for the previous build layer.

6 . The apparatus of claim 1 , further comprising:
at least one build material heating element to heat build material prior to distribution in the build area by the build material distributor, wherein the controller is further to:
prior to controlling the build material distributor to distribute the particular build layer, control the at least one build material heating element to thereby heat build material to be distributed as the particular build layer based at least in part on the build layer temperature of the previous build layer.

7 . The apparatus of claim 6 , wherein the build material distributor comprises at least one pre-delivery receptacle to store build material prior to distribution, the at least one build material heating element is disposed within the pre-delivery receptacle to heat build material stored therein,
wherein the apparatus further comprises at least one pre-delivery receptacle temperature sensor, wherein the controller is further to:
determine a pre-delivery build material temperature with the at least one pre-delivery receptacle temperature sensor, wherein the controller controls the at least one build material heating element to thereby heat the build material to be distributed based at least in part on the pre-delivery build material temperature.

8 . A method for an apparatus for generating a three-dimensional object, the method comprising:
applying energy, with at least one energy source of the apparatus, to a first build layer of build material distributed in a build area of the apparatus; distributing, with a build material distributor of the apparatus, a second build layer of build material in the build area over the first build layer; determining, with at least one build layer temperature sensor, a build layer temperature corresponding to the second build layer; analyzing build layer coverage for locations of the second build layer based at least in part on comparing a build layer temperature of the first build layer and the build layer temperature of the second build layer, and selectively recoating, with the build material distributor, the second build layer with additional build material based at least in part on the build layer coverage for the locations of the second build layer.

9 . The method of claim 8 , further comprising:
prior to distributing the second build layer of build material, pre-heating the build material to be distributed for the second build layer with at least one build material heating element based at least in part on the build layer temperature of the first build layer.

10 . The method of claim 8 , wherein analyzing build layer coverage for the locations of the second build layer comprises determining whether build layer coverage for the second build layer is sufficient or insufficient based at least in part on the build layer temperature for the first build layer and the build layer temperature for the second build layer,
wherein selectively recoating the second build layer with additional build material comprises:
in response to determining that the build layer coverage for the second build layer is insufficient, recoating the second build layer with additional build material with the build material distributor; and
in response to determining that the build layer coverage for the second layer is sufficient, not recoating the second build layer with additional build material and selectively distributing agent on the second build layer with an agent distributor of the apparatus.

11 . The method of claim 8 , wherein analyzing build layer coverage for the second build layer comprises detecting temperature edges for the locations of the second build layer based at least in part on the build layer temperature of the first build layer.

12 . An apparatus for generating a three-dimensional object, the apparatus comprising:
a build material distributor to distribute respective build layers of build material in a build area of the apparatus; at least one build layer temperature sensor; at least one build material heating element to heat build material to be distributed by the build material distributor; and a controller to:
determine a first build layer temperature that corresponds to a first build layer of build material distributed in the build area;
control the at least one build material heating element to pre-heat build material to be distributed on the first build layer based at least in part on the first build layer temperature; and
after pre-heating the build material to be distributed on the first build layer, control the build material distributor to distribute the pre-heated build material as a second build layer on the first layer of build material.

13 . The apparatus of claim 12 , wherein the controller is further to:
determine a second build layer temperature that corresponds to the second build layer; and determine build layer coverage for the second build layer based at least in part on the first build layer temperature and the second build layer temperature.

14 . The apparatus of claim 13 , further comprising:
at least one energy source; and an agent distributor to selectively distribute agent in the build area, wherein the controller is further to:
in response to determining that build layer coverage for the sec

Assignees

• Hewlett Packard Development Co

Inventors

• Vilajosana Xavier
• Cortes I Herms Sebastia
• Ramirez Muela David
• Dominguez Pastor Pablo
• De Pena Alejandro Manuel

Classifications

• B33Y30/00

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

• B29C64/393 Primary

  for controlling or regulating additive manufacturing processes · CPC title

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B33Y50/00

  Data acquisition or data processing for additive manufacturing · CPC title

• B29C64/153

  using layers of powder being selectively joined, e.g. by selective laser sintering or melting · CPC title