Method for controlling printing in three-dimensional printers based on nozzle characteristics

Patent metadata

Field	Value
Publication number	US-9937663-B1
Application number	US-201514613072-A
Country	US
Kind code	B1
Filing date	Feb 3, 2015
Priority date	Feb 4, 2014
Publication date	Apr 10, 2018
Grant date	Apr 10, 2018

Abstract

Embodiments include a method of fabricating a three-dimensional (3D) object using a 3D printing system, wherein the 3D printing system controls one or more parameters of the 3D printing system to fabricate the 3D object, the method comprising: sensing a characteristic of a component of the 3D printing system, wherein the characteristic of the component of the 3D printing system changes over time; and based on sensing a change in the characteristic of the component of the 3D printing system, calibrating a first parameter of the one or more parameters used to fabricate the 3D object.

First claim

What is claimed is:

1. A method of fabricating a three-dimensional (3D) object using a 3D printing system, wherein the 3D printing system controls one or more parameters of the 3D printing system to fabricate the 3D object, the method comprising:
sensing a characteristic of a component of the 3D printing system, wherein the characteristic of the component of the 3D printing system changes over time; and
based on sensing a change in the characteristic of the component of the 3D printing system, calibrating a first parameter of the one or more parameters used to fabricate the 3D object,
wherein the component of the 3D printing system comprises a nozzle, wherein the nozzle has an opening through which printing material is deposited while fabricating the 3D object, and wherein sensing the characteristic of the component comprises
sensing a characteristic of the opening of the nozzle, wherein the characteristic of the opening of the nozzle comprises one or both of (i) a shape of the opening of the nozzle or (ii) a size of the opening of the nozzle.

2. The method of claim 1 , wherein sensing the characteristic of the nozzle comprises:
using one of an optical sensor or a laser scanner to sense the characteristic of the nozzle.

3. The method of claim 1 , wherein calibrating the first parameter of the one or more parameters further comprises:
calibrating the first parameter of the one or more parameters to compensate for any wear and tear in the nozzle.

4. The method of claim 1 , wherein calibrating the first parameter of the one or more parameters used to fabricate the 3D object further comprises:
based at least in part on sensing the characteristic of the nozzle, controlling one of (i) a speed with which the nozzle is driven over a build platform, (ii) a rate with which the printing material is driven through the nozzle, (iii) a temperature at which the printing material is heated, prior to the printing material being deposited via the nozzle, or (iv) a distance between an opening of the nozzle and the build platform.

5. The method of claim 1 , wherein the method further comprises:
while the nozzle deposits the printing material, (i) driving the nozzle over a build platform at a first speed and at a first direction, and (ii) driving the nozzle over the build platform at a second speed and at a second direction, wherein the first direction is different from the second direction,
wherein calibrating the first parameter of the one or more parameters used to fabricate the 3D object further comprises
based at least in part on sensing that at least the shape of the opening of the nozzle has changed to a non-circular shape, controlling the first speed and the second speed such that the first speed is different from the second speed.

6. The method of claim 1 , wherein the characteristic of the nozzle comprises at least a shape of an opening of the nozzle, and wherein the method further comprises:
while driving the nozzle over a build platform at a first direction, operating the nozzle under first operating conditions; and
while driving the nozzle over the build platform at a second direction, operating the nozzle under second operating conditions, wherein the first direction is different from the second direction,
wherein calibrating the first parameter of the one or more parameters used to fabricate the 3D object further comprises
based at least in part on sensing that the shape of the opening of the nozzle has changed to a non-circular shape, controlling the first operating conditions and the second operating conditions such that one or more conditions of the first operating conditions are different from one or more corresponding conditions of the second operating conditions.

7. The method of claim 1 , further comprising:
determining that the sensed change in the characteristic of the nozzle exceeds a threshold value; and
based at least in part on determining that the sensed change in the characteristic of the nozzle exceeds the threshold value, providing a notification notifying that the sensed change in the characteristic of the nozzle exceeds the threshold characteristic.

8. The method of claim 1 , further comprising:
determining that the sensed change in the characteristic of the nozzle exceeds a threshold value; and
based at least in part on determining that the sensed change in the characteristic of the nozzle exceeds the threshold value, providing a notification recommending that the nozzle be replaced with a new nozzle.

9. The method of claim 1 , wherein calibrating the first parameter of the one or more parameters used to fabricate the 3D object further comprises:
determining that the sensed change in the characteristic of the component exceeds a threshold value; and
based at least in part on determining that the sensed change in the characteristic of the component exceeds the threshold value, calibrating the first parameter of the one or more parameters used to fabricate the 3D object.

Assignees

• Marvell Int Ltd

Inventors

• Goss Steven M
• Carlson Gregory F
• Salvatori Phillip
• Mealy James

Classifications

• B29C64/118

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

• B29C67/0055 Primary

  Operations & Transport · mapped topic

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B29C64/112 Primary

  using individual droplets, e.g. from jetting heads · CPC title