US 10,421,267 B2Granted

Method to monitor additive manufacturing process for detection and in-situ correction of defects

AssigneeArevo, Inc.

InventorsRiley Reese, Hemant Bheda, Wiener Mondesir

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Abstract

The present invention provides a system and a method for real time monitoring and identifying defects occurring in a three dimensional object build via an additive manufacturing process. Further, the present invention provides in-situ correction of such defects by a plurality of functional tool heads possessing freedom of motion in arbitrary planes and approach, where the functional tool heads are automatically and independently controlled based on a feedback analysis from the printing process, implementing analyzing techniques. Furthermore, the present invention provides a mechanism for analyzing defected data collected from detection devices and correcting tool path instructions and object model in-situ during construction of a 3D object. A build report is also generated that displays, in 3D space, the structural geometry and inherent properties of a final build object along with the features of corrected and uncorrected defects. Advantageously, the build report helps in improving 3D printing process for subsequent objects.

Claims33

Dependent claims

A system for printing at least a portion of a three dimensional object, said system comprising:

a first engine configured to generate a set of fused filament fabrication tool path instructions for three dimensional printing of the at least the portion of the three dimensional object;
at least one tool head to perform three dimensional printing implementing the fused filament fabrication tool path instructions;
at least one monitoring device for real time monitoring and detecting one or more defects generated in the at least the portion of the three dimensional object;
a controller in operational communication with the at least one monitoring device, wherein the controller is configured to, while printing the at least the portion of the three dimensional object:
(i) use the at least one monitoring device for real time monitoring and detecting of the one or more defects generated in the at least the portion of the three dimensional object;
(ii) generate a set of correcting instructions for controlling the at least one tool head to correct for the one or more defects in a previously printed portion of the at least the portion of the three dimensional object while printing the at least the portion of the three dimensional object, wherein the set of correcting instructions are configured to direct the at least one tool head to modify a structure of the previously printed portion of the at least the portion of the three dimensional object;
and
(iii) communicate with the first engine and instruct the first engine to use the set of correcting instructions to modify or update the set of fused filament fabrication tool path instructions in response to the one or more defects.

5 more elements

A method for printing at least a portion of a three dimensional object, the method comprising:

(a) inputting a data file defining at least one characteristic of the at least the portion of the three dimensional object;
(b) discretizing the data file into a plurality of printable segments to generate a set of fused filament fabrication tool path instructions, by a first engine;
(c) printing the at least the portion of the three dimensional object by at least one tool head, implementing the set of fused filament fabrication tool path instructions generated by the first engine;
(d) while printing the at least the portion of the three dimensional object:
(i) monitoring the printing in real time by at least one monitoring device for detecting one or more defects produced in the at least the portion of the three dimensional object during the printing;
(ii) generating a set of correcting instructions for controlling the at least one tool head to correct the one or more defects in a previously printed portion of the at least the portion of the three dimensional object, wherein the set of correcting instructions is configured to direct the at least one tool head to modify a structure of the previously printed portion of the at least the portion of the three dimensional object;
and
(iii) using the set of correcting instructions to modify or update the set of fused filament fabrication tool path instructions by the first engine in response to the one or more defects.

5 more elements

Dependencies are inferred from the claim text.

Facts

Application: 14/621,205Filed 12 Feb 2015
Published: US 2016/0236414 A118 Aug 2016
Granted: 24 Sep 2019
Term ends: Not estimatedThe source records don’t support an estimate.

Classification12 codes

G05B 19/4099
Characterised by using design data to control NC machines, e.g. CAD/CAM: surface or curve machining, making three-dimensional [3D] objects, e.g.…
B29C 64/393
Data acquisition or data processing for additive manufacturing: for controlling or regulating additive manufacturing processes
B33Y 50/02
Data acquisition or data processing for additive manufacturing: for controlling or regulating additive manufacturing processes
G05B 19/41875
Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible…:…