Systems and methods for compensating for 3D shape deviations in additive manufacturing
AssigneeUniversity of Southern California
InventorsQiang Sean Huang, He Luan, Yuan Jin
Life of this patent
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Abstract
Methods and systems for predicting deformation error and compensating for shape deviation in Additive Manufacturing (AM) techniques include, in one aspect, a method including: obtaining a deformation model for an AM machine; predicting deformation for the object using the deformation model applied to the 3D model; selecting an amount of deformation compensation to effect by minimizing deviation for the predicted deformation; and providing the selected amount of deformation compensation to modify the 3D model to compensate for deformation during creation by the AM machine.
Claims15
A method performed by a computer system comprising processor electronics and at least one memory device, the method comprising:
- obtaining a deformation model for an additive manufacturing (AM) machine, the deformation model representing deformation in a Spherical Coordinate System (SCS) including a first angular location variable and a second angular location variable, wherein the deformation model includes an in-plane deformation error model defined in a first Polar Coordinate System (PCS) using the first angular location variable from the SCS, and the deformation model includes an out-of-plane deformation error model defined in a second PCS using the second angular location variable from the SCS;
- receiving a three dimensional (3D) model of an object to be built using the AM machine;
- predicting deformation for the object using the deformation model applied to the 3D model, wherein the predicting comprises calculating for a given point on the 3D model separate in-plane and out-of-plane error components using the respective in-plane deformation error model and out-of-plane deformation error model;
- selecting an amount of deformation compensation to effect by minimizing deviation for the predicted deformation;
- and
- providing the selected amount of deformation compensation to modify the 3D model to compensate for deformation during creation by the AM machine;
- wherein the deformation model for the AM machine is generated using a cookie-cutter model to trim a polygon from a cylinder, and the cookie-cutter model comprises a periodic waveform having an amplitude that alternates at a steady frequency between fixed minimum and maximum values.
A system comprising:
- an additive manufacturing (AM) machine;
- and
- one or more computing devices coupled with the AM machine and programed to (i) obtain a deformation model for the AM machine, the deformation model representing deformation in a Spherical Coordinate System (SCS) including a first angular location variable and a second angular location variable, wherein the deformation model includes an in-plane deformation error model defined in a first Polar Coordinate System (PCS) using the first angular location variable from the SCS, and the deformation model includes an out-of-plane deformation error model defined in a second PCS using the second angular location variable from the SCS;
- (ii) receive a three dimensional (3D) model of an object to be built using the AM machine;
- (iii) predict deformation for the object using the deformation model applied to the 3D model, wherein the predicting comprises calculating for a given point on the 3D model separate in-plane and out-of-plane error components using the respective in-plane deformation error model and out-of-plane deformation error model;
- (iv) select an amount of deformation compensation to effect by minimizing volume deviation in the SCS for the predicted deformation;
- and (v) provide the selected amount of deformation compensation to modify the 3D model to compensate for deformation during creation by the AM machine;
- wherein the deformation model for the AM machine is generated using a cookie-cutter model to trim a polygon from a cylinder, and the cookie-cutter model comprises a periodic waveform having an amplitude that alternates at a steady frequency between fixed minimum and maximum values.
Dependencies are inferred from the claim text.