Method for forming overhanging structures in additive manufactured parts that have an improved surface roughness
AssigneeAdditive Technologies LLC
InventorsPriyaankaDevi Guggilapu, Benjamin Paulson, Dinesh Krishna Kumar Jayabal, Collin A. Ladd, Stuart A. Schweid
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Abstract
A method for operating a three-dimensional (3D) metal object manufacturing apparatus compensates for surface deviations of overhanging features differently than for non-overhanging features. The compensation method used for the overhanging features depends on whether an edge of the overhanging feature being formed in a next layer has curved or sharp corners.
Claims20
A method of operating an additive manufacturing drop ejecting apparatus comprising:
- generating digital image data of an uppermost layer in an object being formed with drops of a material ejected from the drop ejecting apparatus;
- modifying machine-ready instructions used to operate the drop ejecting apparatus to form an overhanging feature of a next layer of the object using a first correction method and the generated digital image data;
- modifying machine-ready instructions used to operate the drop ejecting apparatus to form a non-overhanging feature of the next layer of the object using a second correction method and the generated digital image data, the second correction method being different than the first correction method;
- and
- executing the modified machine-ready instructions to operate the drop ejecting apparatus to form the next layer of the object.
A method of operating an additive manufacturing drop ejecting apparatus comprising:
- generating digital image data of an uppermost layer in an object being formed with drops of a material ejected from the drop ejecting apparatus;
- modifying machine-ready instructions used to operate the drop ejecting apparatus to form an overhanging feature of a next layer of the object using an offset-based semi-local correction method and the generated digital image data;
- modifying machine-ready instructions used to operate the drop ejecting apparatus to form a non-overhanging feature of the next layer of the object using a local correction method and the generated digital image data;
- and
- executing the modified machine-ready instructions to operate the drop ejecting apparatus to form the next layer of the object.
A method of operating an additive manufacturing drop ejecting apparatus comprising:
- generating digital image data of an uppermost layer in an object being formed with drops of a material ejected from the drop ejecting apparatus;
- modifying machine-ready instructions used to operate the drop ejecting apparatus to form an overhanging feature of a next layer of the object using a first correction method and the generated digital image data;
- modifying machine-ready instructions used to operate the drop ejecting apparatus to form a non-overhanging feature of the next layer of the object using a second correction method and the generated digital image data, the second correction method being different than the first correction method;
- generating a gain map using the generated digital image data, the first correction method using a first portion of the gain map to identify changes to be made to the machine-ready instructions that form the overhanging feature and the second correction method using a second portion of the gain map to identify changes to be made to the machine-ready instructions that form the non-overhanging feature;
- and
- executing the modified machine-ready instructions to operate the drop ejecting apparatus to form the next layer of the object.
Dependencies are inferred from the claim text.