# US 12,766,783 B2 · Additive manufacturing method > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,766,783 B2 - Document ID: US12766783B2 - Status: Granted - Kind: B2 - Application number: 17/999,134 - Filed: 2021-05-14 - Published: 2023-06-22 - Granted: 2026-10-20 - Earliest claimed: 2020-05-20 - Assignees: Kobe Steel, Ltd. - Applicants: Kobe Steel, Ltd. - Inventors: Akinori Yoshikawa; Masatoshi Hida - Web page: https://patentgrep.com/patent/US12766783B2 ## CPC - B29C 64/118: using filamentary material being melted, e.g. fused deposition modelling [FDM] - B23K 9/032: for three-dimensional [3D] seams - B23K 9/04: Welding for other purposes than joining, e.g. built-up welding - B23K 9/0956: {using sensing means, e.g. optical} - B29C 64/393: for controlling or regulating additive manufacturing processes - B33Y 10/00: Processes of additive manufacturing - B33Y 50/02: for controlling or regulating additive manufacturing processes - 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) - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM - 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 The shape profile of an existing weld bead is measured by a non-contact type shape sensor provided integrally with a welding torch on a robot tip end shaft, midway through molding of a laminate molded object on the basis of a lamination trajectory plan. First geometric information relating to the bead shape is extracted from the shape profile and the target position of the welding torch, second geometric information corresponding to the first geometric information is extracted from the deposition track plan, and an offset amount is calculated from the first geometric information and the second geometric information. In accordance with the offset amount, the deposition track plan is updated by updating at least one of the bead height and the bead width of the weld bead determined by the deposition track plan, and the welding conditions are updated in accordance with the update result of the deposition track plan. ## Claims ### Claim 1 An additive manufacturing method of depositing weld beads formed by melting and solidifying a filler metal while moving a welding torch attached to a robot tip shaft, the additive manufacturing method comprising: a step of measuring a shape profile of an existing weld bead by a non-contact shape sensor provided on the robot tip shaft integrally with the welding torch, during manufacture of an additively-manufactured object by forming the weld beads, based on a stored deposition track plan based on predetermined shape data of the additively-manufactured object and comprising a program for manufacturing the additively-manufactured object, the deposition track plan defining a target position of the welding torch and a shape of the weld beads; a step of extracting first geometric information of a bead shape from the shape profile and the target position of the welding torch; a step of extracting second geometric information corresponding to the first geometric information from the deposition track plan and calculating a deviation amount between the first geometric information and the second geometric information; a step of updating the deposition track plan by changing at least one of a bead height and a bead width in a cross section perpendicular to a bead longitudinal direction of the weld bead defined by the deposition track plan, according to the deviation amount; and a step of changing a welding condition according to an update result of the deposition track plan, wherein the first geometric information and the second geometric information include information on at least a geometric feature point near the target position of the welding torch, and the geometric feature point includes an end point of a narrowed portion formed by recessing a bead outer surface inward between the weld bead and another weld bead adjacent to the weld bead. ### Claim 2 (depends on 1) The additive manufacturing method according to claim 1, wherein the geometric feature point is extracted from the existing weld bead located near the target position of the welding torch. ### Claim 3 (depends on 1) The additive manufacturing method according to claim 1, wherein in the step of changing the welding condition, at least one or a combination of two or more of a position of the welding torch, a posture of the welding torch, a welding speed, a welding voltage, a welding current, and a feeding speed of the filler metal is changed. ### Claim 4 (depends on 1) The additive manufacturing method according to claim 1, wherein the shape profile is a cross-sectional shape of the existing weld bead including an axis of the welding torch at the target position of the welding torch, which is inclined at a predetermined angle from a plane parallel to a detection direction of the weld bead by the non-contact shape sensor. ### Claim 5 (depends on 4) The additive manufacturing method according to claim 4, wherein the geometric feature point is extracted from the existing weld bead located near the target position of the welding torch. ### Claim 6 (depends on 4) The additive manufacturing method according to claim 4, wherein in the step of changing the welding condition, at least one or a combination of two or more of a position of the welding torch, a posture of the welding torch, a welding speed, a welding voltage, a welding current, or a feeding speed of the filler metal is changed. ### Claim 7 (depends on 2) The additive manufacturing method according to claim 2, wherein in the step of changing the welding condition, at least one or a combination of two or more of a position of the welding torch, a posture of the welding torch, a welding speed, a welding voltage, a welding current, and a feeding speed of the filler metal is changed. ### Claim 8 (depends on 1) The additive manufacturing method according to claim 1, wherein the geometric feature point includes a point where an end portion of the weld bead in a width direction and a lower layer surface on which the weld bead is formed intersect. ### Claim 9 An additive manufacturing method of depositing weld beads formed by melting and solidifying a filler metal while moving a welding torch attached to a robot tip shaft, the additive manufacturing method comprising: a step of measuring a shape profile of an existing weld bead by a non-contact shape sensor provided on the robot tip shaft integrally with the welding torch, during manufacture of an additively-manufactured object by forming the weld beads, based on a stored deposition track plan based on predetermined shape data of the additively-manufactured object and comprising a program for manufacturing the additively-manufactured object, the deposition track plan defining a target position of the welding torch and a shape of the weld beads; a step of extracting first geometric information of a bead shape from the shape profile and the target position of the welding torch; a step of extracting second geometric information corresponding to the first geometric information from the deposition track plan and calculating a deviation amount between the first geometric information and the second geometric information; a step of updating the deposition track plan by changing at least one of a bead height and a bead width in a cross section perpendicular to a bead longitudinal direction of the weld bead defined by the deposition track plan, according to the deviation amount; and a step of changing a welding condition according to an update result of the deposition track plan, wherein the first geometric information and the second geometric information include information on at least a geometric feature point near the target position of the welding torch, and the geometric feature point includes an apex of a convex shape of the existing weld bead, an end point of a narrowed portion formed by recessing a bead outer surface inward between the weld bead and another weld bead adjacent to the weld bead, and a point where an end portion of the weld bead in a width direction and a lower layer surface on which the weld bead is formed intersect.