Systems and methods for adjusting a three-dimensional (3d) model during additive manufacturing

Patent metadata

Field	Value
Publication number	US-2023264423-A1
Application number	US-202318108639-A
Country	US
Kind code	A1
Filing date	Feb 12, 2023
Priority date	Jun 26, 2018
Publication date	Aug 24, 2023
Grant date	—

Abstract

Embodiments of the present disclosure are drawn to systems and methods for adjusting a three-dimensional (3D) model used in metal additive manufacturing to maintain dimensional accuracy and repeatability of a fabricated 3D part. These embodiments may be used to reduce or remove geometric distortions in the fabricated 3D part. One exemplary method may include: receiving, via one or more processors, a selection made by a user; receiving a 3D model of a desired part; retrieving at least one model constant based on the user's selection; receiving an input of at least one process variable setting from a set of process variable settings; generating transformation factors based on the at least one process variable parameter and the at least one model constant; transforming the 3D model of the desired part based on the transformation factors; and generating processing instructions for fabricating the transformed 3D model of the desired part.

First claim

1 . A method for maintaining dimensional accuracy of a fabricated three-dimensional (3D) part by adjusting a 3D model used in metal additive manufacturing, comprising:
receiving, using a processor, a selection for fabricating a desired 3D part; receiving a 3D model of the desired 3D part; retrieving at least one model constant based on the selection; receiving an input of at least one process variable parameter from a set of process variable parameters; generating transformation factors based on the at least one process variable parameter and the at least one model constant; transforming the 3D model of the desired part based on the transformation factors; and generating processing instructions for fabricating the transformed 3D model of the desired part.

2 . The method of claim 1 , wherein the selection comprises a process selection, a hardware selection, and a build material selection.

3 . The method of claim 1 , wherein the at least one process variable parameter from the set of process variable parameters is an adjustable process variable in a 3D fabrication system.

4 . The method of claim 1 , wherein the at least one process variable parameter, comprises:
controlling a layer height of a deposited bead of material, selecting a print speed, controlling a bead width of a deposited bead of material, controlling a temperature within a sintering furnace, and controlling the chemistry within a sintering furnace.

5 . The method of claim 3 , wherein the 3 D fabrication system is an extrusion-based fabrication process.

6 . The method of claim 3 , wherein the 3 D fabrication system is a binder jetting fabrication process.

7 . The method of claim 1 , wherein the 3D model is transformed by at least one of a scaling operation, an offsetting operation, a shearing operation, a rotation operation, a stretching operation, and a squeezing operation.

8 . The method of claim 1 , wherein the transformation factors comprise scaling factors and constant offsets to at least one model dimension of the 3D model.

9 . The method of claim 1 . wherein transforming the 3D model of the desired part based on the transformation factors comprises stretching or scaling the 3D model along one or more of X-, Y-, or Z-axes of the 3D model.

10 . The method of claim 1 , further comprising:
fabricating the transformed model part using a 3D fabrication system; and repeating the steps of receiving an input of at least one process variable parameter from a set of process variable parameters, generating transformation factors based on the at least one process variable parameter and the at least one model constant, transforming the 3D model of the desired part based on the transformation factors, and generating process instructions for fabricating the transformed 3D model of the desired part.

11 . The method of claim 1 , w herein the at least one model constant is a set of model constants.

12 . The method of claim 11 , wherein the set of model constants are generated based on a regression model.

13 . A method for maintaining dimensional accuracy of a fabricated three-dimensional (3D) part by adjusting a 3D model used in metal additive manufacturing, comprising:
receiving, using a processor, a selection for fabricating a desired 3D part; receiving a 3D model of the desired 3 D part; receiving an input of at least one process variable parameter from a set of process variable parameters; retrieving at least one model and at least one associated model constant based on the selection; generating transformation factors based on the at least one process variable parameter and the at least one model constant; transforming the 3D model of the desired part based on the transformation factors, and generating processing instructions for fabricating the transformed 3D model of the desired part.

14 . The method of claim 13 , wherein the selection comprises a process selection, a hardware selection, and a build material selection.

15 . The method of claim 13 , wherein the at least one process variable parameter from the set of process variable parameters is an adjustable process variable in a 3D fabrication system.

16 . The method of claim 15 , wherein the 3D fabrication system is an extrusion-based fabrication process.

17 . The method of claim 15 , wherein the 3D fabrication system is a binder jetting fabrication process.

18 . The method of claim 13 , w-herein transforming the 3D model of the desired part based on the transformation factors comprises stretching or scaling the 3D model along one or more of X-, Y-, or Z-axes of the 3D model.

19 . The method of claim 13 , wherein the 3D model is transformed by at least one of a scaling operation, an offsetting operation, a shearing operation, a rotation operation, a stretching operation, and a squeezing operation.

20 . A system for adjusting a three-dimensional (3D) model used in metal additive manufacturing, comprising:
a processor configured to: receive, using a processor, a selection for fabricating a desired 3D part, receive a 3D model of the desired 3D part; retrieve at least one model constant based on the selection; receive an input of at least one process variable parameter from a set of process variable parameters; generate transformation factors based on the at least one process variable parameter and the at least one model constant; transform the 3D model of the desired part based on the transformation factors; and generate processing instructions for fabricating the transformed 3 D model of the desired part.

21 . (canceled)

Assignees

• Desktop Metal Inc

Inventors

• Barbati Alexander
• Gibson Michael
• Hudelson George
• Mykulowycz Nicholas
• Kernan Brian
• Tuncer Nihan

Classifications

• B29C64/393 Primary

  for controlling or regulating additive manufacturing processes · CPC title

• B29C64/118

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · 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

• B29C64/379

  Handling of additively manufactured objects, e.g. using robots · CPC title

• B33Y50/02 Primary

  for controlling or regulating additive manufacturing processes · CPC title