Systems and methods for calibration feedback for additive manufacturing

Patent metadata

Field	Value
Publication number	US-2019329322-A1
Application number	US-201916508882-A
Country	US
Kind code	A1
Filing date	Jul 11, 2019
Priority date	Apr 14, 2017
Publication date	Oct 31, 2019
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

1 - 22 . (canceled)

23 . A method for additive manufacturing of three-dimensional metal objects, the method comprising:
printing a plurality of layers to form an object on a print surface, wherein the plurality of layers are printed layer-by-layer; scanning each of the plurality of layers to obtain scan data for each of the plurality of layers; generating a map based on the scan data of each of the plurality of layers; determining whether one or more defects exist based on the map; changing a print configuration if it is determined that the one or more defects exist; and printing a subsequent object using the changed print configuration.

24 . The method according to claim 23 , wherein changing the print configuration includes changing at least one of a toolpath of a print head of a printer or a flow rate of a build material deposited by the print head.

25 . The method according to claim 23 , wherein determining whether one or more defects of the printed object exist includes comparing a model of the object with the map of the printed object.

26 . The method according to claim 25 , further comprising modifying a geometry of the model of the object if the one or more defects exist.

27 . The method according to claim 23 , wherein determining whether one or more defects of the printed object exist includes comparing the scan data for each of the plurality of layers in the map to each corresponding layer of a model of the object.

28 . The method according to claim 23 , further comprising generating print parameters defining geometry of the printed object with offsets to a model of the object.

29 . The method according to claim 23 , wherein the one or more defects include a discrepancy between a tool path of a print head used to print the object and the printed object.

30 . A method for additive manufacturing of metal objects, the method comprising:
printing a three-dimensional (3D) object on a print surface; acquiring image data of the 3D object; generating an image of the 3D object; comparing at least one of the image data or the image to an initial model of the 3D object; determining whether one or more discrepancies exist between the at least one of the image data or the image and the initial model of the 3D object; and changing a print configuration for printing the 3D object if the one or more discrepancies exist.

31 . The method according to claim 30 , wherein the printed 3D object includes a plurality of intersecting lines or one or more geometric shapes, and wherein the determining if the one or more discrepancies exists includes comparing at least one of (1) the image data or the image of the plurality of intersecting lines or the image data, or (2) the image of the one or more geometric shapes to the initial model of the 3D object.

32 . The method according to claim 30 , wherein the printed 3D object includes a plurality of parallel lines printed by a plurality of respective printer nozzles, and wherein the determining if the one or more discrepancies exists includes comparing image data or image of the plurality of parallel lines to determine if the lines are parallel.

33 . The method according to claim 30 , wherein changing the print configuration includes modifying a geometry of the initial model of the 3D object based on the one or more discrepancies between the initial model of the 3D object and the image data or image, or generating an updated tool path based on the one or more discrepancies between the initial model of the 3D object and the image data or the image.

34 . The method according to claim 30 , wherein the acquiring the image data is concurrently performed with the printing the 3D object.

35 . The method according to claim 30 , wherein acquiring the image data includes capturing a plurality of scans of the printed 3D object, the method further comprising stitching together the plurality of scans to generate the image of the printed 3D object.

36 . The method according to claim 30 , wherein the printed 3D object is printed from a metal build material, the method further comprising depositing an intermediate layer, including a material different from the metal build material, on a topmost surface of the printed 3D object, and printing a subsequent object on a topmost surface of the intermediate layer.

37 . The method according to claim 30 , wherein after printing the 3D object, the method further comprises:
printing a subsequent 3D object; acquiring image data of the subsequent printed 3D object; generating an image of the subsequent 3D object; comparing at least one of the image data or the image of the subsequent printed 3D object to the initial model of the 3D object; determining whether one or more discrepancies exist between the image data or the image of the subsequent 3D object and the initial model of the subsequent 3D object; and changing the print configuration for printing the subsequent 3D object if it is determined the one or more discrepancies exist.

38 . The method according to claim 30 , further comprising generating a vector map from the image data to determine a positional offset between the initial model of the 3D object and a toolpath of a nozzle used to print the 3D object.

39 . A method for additive manufacturing of metal objects, the method comprising:
scanning a printed object to generate scan data; generating a map of the printed object; determining whether there is a defect in the printed object; changing a print configuration if the printed object includes the defect; and printing a subsequent object using the changed print configuration.

40 . The method according to claim 39 , further comprising:
generating print parameters based on an initial model of the printed object and the scan data, wherein the print parameters define a geometry of the subsequent object.

41 . The method according to claim 39 , further comprising:
scanning a print surface; determining if a surface defect exists on the print surface; and changing the print configuration if the surface defect exists on the print surface, wherein changing the print configuration further includes one or more of (1) orienting an offset plane of the object to be printed to correspond to an orientation of a plane of the print surface, or (2) selecting an area of the build plate that does not contain the defect on which to print the object.

42 . The method according to claim 41 , wherein, if the surface defect exists on the print surface, the method further comprises:
printing a metal build material into the surface defect; depositing an intermediate layer of a second material, different from the metal build material, onto the print surface and the metal build material deposited in the defect; and printing the subsequent object on a surface of the intermediate layer.

43 . The method according to claim 39 , further comprising generating image data of the printed object, wherein generating the image data of the printed object comprises stitching together a plurality of scans.

44 . The method according to claim 39 , wherein changing the print configuration includes modifying a geometry of an initial model of the printed object prior to printing the subsequent object based on one or more discrepancies between the initial model of the printed object and the scan data, or generating an updated tool path based on the discrepancies between the initial model of the printed object and the scan data.

Assignees

• Desktop Metal Inc

Inventors

• Preston Aaron
• Mykulowycz Nicholas

Classifications

• B22F3/22 Primary

  for producing castings from a slip · CPC title

• B29C64/386

  Data acquisition or data processing for additive manufacturing · CPC title

• B29C64/165

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title

• B22F10/31

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

• B22F10/38

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