# US 10,118,345 B2 · System and method for evaluation of a three-dimensional (3D) object during formation of the object > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,118,345 B2 - Document ID: US10118345B2 - Status: Granted - Kind: B2 - Application number: 14/742,189 - Filed: 2015-06-17 - Published: 2016-12-22 - Granted: 2018-11-06 - Earliest claimed: 2015-06-17 - Assignees: Xerox Corporation - Applicants: Xerox Corporation - Inventors: Guido N. Dimatteo; James A. Dunst; David R. Kamprath - Web page: https://patentgrep.com/patent/US10118345B2 ## CPC - G05B 19/4097: characterised by using design data to control NC machines, e.g. CAD/CAM (G05B19/4093 takes precedence) - B29C 64/393: for controlling or regulating additive manufacturing processes - G05B 19/4099: Surface or curve machining, making three-dimensional [3D] objects, e.g. desktop manufacturing - B33Y 50/02: for controlling or regulating additive manufacturing processes - G05B 2219/37205: Compare measured, vision data with computer model, cad data - G05B 2219/49023: 3-D printing, layer of powder, add drops of binder in layer, new powder - G05B 2219/50063: Probe, measure, verify workpiece, feedback measured values - G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING ## Abstract A method for evaluating a three-dimensional (3D) object produced by a three-dimensional (3D) object printer includes generating with a scanner a first data file of the 3D object produced by the three-dimensional object printer. The first data file includes data corresponding to an interior surface and an exterior surface of the 3D object. The method further includes comparing the first data file with a second data file. The second data file is used to operate the three-dimensional object printer to produce the 3D object. The method further includes identifying differences between the first data file and the second data file and identifying a process to rectify a defect on the 3D object based on the identified differences to enable evaluation of the production of the 3D object by the three-dimensional object printer. ## Claims ### Claim 1 A method for evaluating a three-dimensional (3D) object produced by a three-dimensional object printer comprising: generating with a scanner image data of the 3D object produced by the three-dimensional object printer in a first data file, the image data of the 3D object corresponding to an interior surface and an exterior surface of the 3D object; operating the three-dimensional object printer with data in a second data file that corresponds to the 3D object to produce the 3D object and to form indicia on a surface of the 3D object during production of the 3D object prior to generating the image data in the first data file with the scanner; aligning a position and orientation of the 3D object in the image data of the first data file with a position and orientation of the 3D object in the second data file with reference to the image data of the indicia on the 3D object in the first data file; comparing the image data of the 3D object in the first data file with the data corresponding to the aligned 3D object in the second data file; identifying differences between the image data corresponding to the interior surface and the exterior surface of the 3D object in the first data file and the data corresponding to the aligned 3D object in the second data file; performing a process to add material to or remove material from the 3D object to rectify a defect on the 3D object with reference to the identified differences; generating with the scanner image data of the 3D object in a third data file after the process to rectify the defect is performed, the image data corresponding to the interior surface and the exterior surface of the 3D object after the process to rectify the defect is performed; aligning a position and orientation of the 3D object in the third data file with a position and orientation of the 3D object in the second data file with reference to the image data of the indicia on the 3D object in the third data file; comparing the image data of the 3D object in the third data file with the data corresponding to the aligned 3D object in the second data file; identifying differences between the image data corresponding to the interior surface and the exterior surface of the 3D object in the third data file and the data corresponding to the aligned 3D object in the second data file; comparing the identified differences to a predetermined threshold; performing the process to add material to or remove material from the 3D object to rectify the defect on the 3D object with reference to the identified differences in response to the identified differences being greater than the predetermined threshold; and continuing to generate the image data for the third data file, aligning the position and orientation of the 3D object in the third data file with the position and orientation of the aligned 3D object in the second data file, comparing the image data of the 3D object in the third data file with the data corresponding to the aligned 3D object in the second data file, identifying differences between the image data of the 3D object in the third data file and the data of the aligned 3D object in the second data file, comparing the identified differences to the predetermined threshold, and performing the process to add material to or remove material from the 3D object to rectify the defect on the 3D object until the identified differences are less than the predetermined threshold or until the process to rectify the defect has been performed a predetermined number of times. ### Claim 2 (depends on 1) The method of claim 1, the alignment of the image data of the 3D object in the first data file with the data corresponding to the 3D object in the second data file further comprising: correlating image data in the first data file corresponding to the indicia formed on the surface of the 3D object with the data in the second data file used to form the indicia to align the position and orientation of the 3D object in the first data file with the position and orientation of the 3D object in the second data file. ### Claim 3 (depends on 1) The method of claim 1 further comprising: identifying a best fit of the image data in the first data file with the data in the second data file to align the position and orientation of the 3D object in the first data file with the position and orientation of the 3D object in the second data file. ### Claim 4 (depends on 1) The method of claim 1, the generation of the image data in the first data file with the scanner further comprising: scanning the interior surface of the 3D object with at least one of an x-ray, a ultrasound, and a MRI to generate the image data in the first data file. ### Claim 5 (depends on 1) The method of claim 1, the generation of the image data in the first data file with the scanner further comprising: scanning the exterior surface of the 3D object with a three dimensional scanner having at least one light source and at least one light detector for generating a signal corresponding to an intensity of light reflected by the 3D object. ### Claim 6 (depends on 1) The method of claim 1 further comprising: detecting a portion of the 3D object corresponding to image data in the first data file where the data in the second data file does not have a corresponding portion; and identifying a difference in distance between a position for the portion of the 3D object in the first data file and a position for the portion missing from the 3D object in the second data file. ### Claim 7 (depends on 1) The method of claim 1 further comprising: detecting a portion of the 3D object corresponding to image data in the first data file where data in the second data file does not have a corresponding portion; and identifying a difference in volume between the portion of the 3D object in the first data file and the portion missing from the 3D object in the second data file. ### Claim 8 A three-dimensional object printer comprising: a planar member; at least one ejector configured to eject material to produce a three-dimensional (3D) object on the planar member; a scanner configured to generate image data of the 3D object for a first data file, the image data corresponding to an interior surface and an exterior surface of the 3D object; and a controller operatively connected to the at least one ejector and the scanner, the controller being configured to: operate the scanner to generate the image data of the 3D object for the first data file; operate the at least one ejector with reference to a second data file to produce the 3D object; operate the at least one ejector with reference to the second data file to form indicia on a surface of the 3D object during production of the 3D object; align a position and orientation of the 3D object in the image data of the first data file with a position and orientation of the 3D object in the second data file with reference to the image data of the indicia on the 3D object in the first data file; compare the image data of the 3D object in the first data file received from the scanner with the data corresponding to the aligned 3D object in the second data file; identify differences between the image data corresponding to the interior surface and the exterior surface of the 3D object in the first data file and the data corresponding to the aligned 3D object in the second data file; perform a process to add material to or remove material from the 3D object to rectify a defect on the 3D object with reference to the identified differences; generate with the scanner image data of the 3D object in a third data file after the process to rectify the defect is performed, the image data corresponding to the interior surface and the exterior surface of the 3D object after the process to rectify the defect is performed; align a position and orientation of the 3D object in the third data file with the position and orientation of the 3D object in the second data file with reference to the image data of the indicia on the 3D object in the third data file; compare the image data of the 3D object in the third data file with the data corresponding to the 3D object in the second data file; identify differences between the image data corresponding to the interior surface and the exterior surface of the 3D object in the third data file and the data corresponding to the 3D object in the second data file; compare the identified differences to a predetermined threshold; perform a process to add material to or remove material from the 3D object to rectify the defect on the 3D object with reference to the identified differences in response to the identified differences being greater than the predetermined threshold; and continue to operate the scanner to generate the image data for the third data file, aligning the position and orientation of the 3D object in the third data file with the position and orientation of the 3D object in the second data file, comparing the image data of the 3D object in the third data file with the data corresponding to the aligned 3D object in the second data file, identifying differences between the image data of the 3D object in the third data file and the data of the aligned 3D object in the second data file, comparing the identified differences to the predetermined threshold, and performing the process to add material to or remove material from the 3D object to rectify the defect on the 3D object until the identified differences are less than the predetermined threshold or until the process to rectify the defect has been performed a predetermined number of times. ### Claim 9 (depends on 8) The printer of claim 8 further comprising: correlate image data in the first data file corresponding to the indicia formed on the surface of the 3D object with the data in the second data file used to form the indicia to align the position and orientation of the 3D object in the first data file with the position and orientation of the 3D object in the second data file. ### Claim 10 (depends on 8) The printer of claim 8, the controller being further configured to: identify a best fit of the image data in the first data file with the data in the second data file to align the position and orientation of the 3D object in the first data file with the position and orientation of the 3D object in the second data file. ### Claim 11 (depends on 8) The printer of claim 8, the scanner further comprising: at least one of an x-ray, a ultrasound, and a MRI to generate image data in the first data file that corresponds to the interior surface of the 3D object. ### Claim 12 (depends on 8) The printer of claim 8, the scanner further comprising: at least one light source and at least one light detector for generating a signal corresponding to an intensity of light reflected by the 3D object to generate image data in the first data file that corresponds to the exterior surface of the 3D object. ### Claim 13 (depends on 8) The printer of claim 8, the controller being further configured to: detect a portion of the 3D object corresponding to image data in the first data file where the data in the second data file does not have a corresponding portion; and identify a difference in distance between a position for the portion of the 3D object in the first data file and a position for the portion missing from the 3D object in the second data file. ### Claim 14 (depends on 8) The printer of claim 8, the controller being further configured to: detect a portion of the 3D object corresponding to image data in the first data file where the data in the second data file does not have a corresponding portion; and identify a difference in volume between the portion of the 3D object in the first data file and the portion missing from the 3D object in the second data file.