Method for multivariate testing, development, and validation of a material for an additive manufacturing device

The method of claim:

• further comprising, during the first time period:
• accessing a set of nominal part characteristic ranges, of the set of part characteristics, for the target part;
• and
• calculating a set of nominal print parameter ranges, of the set of print parameters, for the target part based on the set of nominal part characteristic ranges and the set of functions;
• and
• wherein calculating the first set of print parameter ranges during the second time period comprises recalculating the set of nominal print parameter ranges based on the first target value for the first part characteristic.

The method of claim:

• further comprising, during an initial time period preceding the first time period:
• accessing a first material property of the material;
• identifying a second material associated with a second material property analogous to the first material property;
• and
• extracting a second set of functions associated with the second material from a library of material profiles;
• and
• wherein calculating the set of nominal print parameter ranges during the first time period comprises calculating the set of nominal print parameter ranges based on the second set of functions.

The method of claim:

• further comprising, during the second time period, receiving identification of the user accessing the user interface;
• wherein accessing the set of nominal part characteristic ranges during the first time period comprises extracting a first preferred part characteristic value from a user profile, in a population of user profiles, associated with the user, the first preferred part characteristic value corresponding to the first part characteristic;
• and
• further comprising, during the second time period, presenting the first preferred part characteristic value adjacent the first part characteristic in the user interface.

The method of claim, further comprising, during an initial time period preceding the first time period:

• accessing a first material property of the material;
• identifying a second material associated with a second material property analogous to the first material property;
• assigning the set of test print parameters to the set of test builds based on a second set of test print parameters executed by the set of additive manufacturing systems during fabrication of a second target part formed of the second material;
• generating a test print file for the set of test builds formed of the material based on the set of print parameters;
• and
• serving the test print file to the set of additive manufacturing systems for execution during fabrication of the set of test builds.

The method of claim:

• further comprising, during the first time period:
• accessing a set of nominal part characteristic ranges, of the set of part characteristics, for the target part including a second nominal part characteristic value corresponding to the second part characteristic;
• wherein calculating the second part characteristic range of the second part characteristic during the second time period comprises calculating the second part characteristic range excluding the second nominal part characteristic value;
• and
• further comprising, during the second time period:
• generating a notification comprising a prompt to review the first target value for the first part characteristic;
• and
• transmitting the notification to the user via the user interface.

The method of claim:

• wherein receiving the first target value during the second time period comprises receiving a target dimensional accuracy value corresponding to a dimensional accuracy characteristic from the user via the user interface;
• wherein receiving the second target value during the second time period comprises receiving a target part strength value corresponding to a part strength characteristic from the user via the user interface;
• and
• wherein calculating the second set of print parameter ranges during the second time period comprises calculating an exposure duration range for an exposure duration parameter based on a function representing a relationship between the dimensional accuracy characteristic, the part strength characteristic, and the exposure duration parameter and limited by the target dimensional accuracy value and the target part strength value.

The method of claim:

• wherein receiving the first target value for the first part characteristic during the second time period comprises receiving:
• a first surface finish value corresponding to a first surface of the target part;
• and
• a second surface finish value corresponding to a second surface of the target part;
• wherein calculating the second set of print parameter ranges during the second time period comprises:
• calculating a first layer thickness value based on the first surface finish value;
• and
• calculating a second layer thickness value based on the second surface finish value;
• and
• wherein generating the print file for the target part during the second time period comprises:
• segmenting the virtual model into a set of model layers;
• for a first model layer, in the set of model layers, intersecting the first surface, assigning the first layer thickness value to the first model layer;
• for a second model layer, in the set of model layers, intersecting the second surface, assigning the second layer thickness value to the second model layer;
• and
• compiling the first model layer, the second model layer, the first layer thickness value and the second layer thickness value into a set of print images in the print file for execution by a first additive manufacturing system configured to selectively expose layers of resin according to print images in the print file to manufacture the target part.

The method of claim:

• further comprising, during the second time period, in response to calculating the second set of print parameter ranges comprising an invalid range for a first print parameter:
• generating a notification comprising a prompt to review the first target value for the first part characteristic and the second target value for the second part characteristic;
• and
• transmitting the notification to the user via the user interface.

The method of claim:

• further comprising, during the second time period:
• presenting the first part characteristic, via the user interface, adjacent a first slider, the first slider:
• interposed between a first text box indicating a first lower boundary of a first part characteristic range and a second text box indicating a first upper boundary of the first part characteristic range;
• and
• configured for adjustability by the user to receive the first target value corresponding to the first part characteristic;
• and
• presenting the second part characteristic, via the user interface, adjacent a second slider, the second slider:
• interposed between a third text box indicating a second lower boundary of the second part characteristic range and a fourth text box indicating a second upper boundary of the second part characteristic range;
• and
• configured for adjustability by the user to receive the second target value corresponding to the second part characteristic;
• wherein receiving the first target value from the user during the second time period comprises receiving the first target value via adjustment of the first slider by the user;
• and,
• wherein receiving the second target value from the user during the second time period comprises receiving the second target value via adjustment of the second slider by the user.

The method of claim:

• further comprising, during an initial time period preceding the first time period:
• accessing a subset of functions, in the set of functions, associated with the first part characteristic and the second part characteristic;
• and
• calculating the second lower boundary and the second upper boundary of the second part characteristic range based on the subset of functions;
• wherein presenting the second part characteristic during the second time period comprises presenting the second part characteristic, via the user interface, adjacent the second slider by:
• populating the third text box with the second lower boundary of the second part characteristic range;
• and
• populating the fourth text box with the second upper boundary of the second part characteristic range;
• and
• further comprising, in response to receiving the first target value, for the first part characteristic:
• recalculating an updated lower boundary and an updated upper boundary of the second part characteristic range based on the set of functions and limited by the first set of print parameter ranges;
• populating the third text box with the updated lower boundary of the second part characteristic range;
• and
• populating the fourth text box with the updated upper boundary of the second part characteristic range.

The method of claim:

• wherein accessing the set of test characteristics representing dimensional properties and mechanical properties of the set of test builds formed of the material during the first time period comprises:
• for a first test build, in the set of test builds, extracting a first surface finish value and a first dimensional accuracy value of the first test build from the set of test characteristics;
• and
• for a second test build, in the set of test builds, extracting a second surface finish value and a second dimensional accuracy value of the second test build from the set of test characteristics;
• wherein accessing the set of test print parameters executed by the set of additive manufacturing systems during fabrication of the set of test builds during the first time period comprises:
• for the first test build, accessing a first exposure duration and a first layer thickness;
• and
• for the second test build, accessing a second exposure duration less than the first exposure duration and a second layer thickness greater than the first layer thickness;
• and
• wherein deriving the set of functions for the material during the first time period comprises:
• deriving a first function representing a first relationship between a surface finish characteristic and an exposure duration parameter based on the second surface finish value less than the first surface finish value and the second exposure duration less than the first exposure duration;
• deriving a second function representing a second relationship between the surface finish characteristic and a layer thickness parameter based on the second surface finish value less than the first surface finish value and the second layer thickness greater than the first layer thickness;
• deriving a third function representing a third relationship between a dimensional accuracy characteristic and the exposure duration parameter based on the second dimensional accuracy value less than the first dimensional accuracy value and the second exposure duration less than the first exposure duration;
• and
• deriving a fourth function representing a fourth relationship between the dimensional accuracy characteristic and the layer thickness parameter based on the second dimensional accuracy value less than the first dimensional accuracy value and the second layer thickness greater than the first layer thickness.

The method of claim, further comprising:

• during an initial time period preceding the first time period:
• generating a cure characterization test file defining a first set of test builds arranged across a build area, each test build characterized by a total exposure energy value;
• photocuring the first set of test builds by, for each test build, selectively exposing the material to an exposure energy corresponding to the total exposure energy value characterizing the test build;
• accessing a first set of physical measurements representing a depth of cure for each test build;
• calculating a working curve of the material based on the first set of physical measurements;
• for assessing a dimensional accuracy characteristic:
• generating a second test file based on the working curve of the material, the second test file defining the set of test builds, each test build in the set of test builds:
• characterized by an exposure intensity value and an exposure duration value corresponding to a total exposure energy value greater than a target exposure energy of the material;
• defining a positive stepped pyramid, each level of the positive stepped pyramid characterized by a positive target dimension;
• and
• defining a negative stepped pyramid, each level of the negative stepped pyramid characterized by a negative target dimension;
• and
• photocuring the set of test builds based on the second test file by, for each test build in the set of test builds:
• photocuring volumes of the material via exposure to electromagnetic radiation, according to the exposure intensity value and the exposure duration value characterizing the test build, to form a positive stepped pyramid of the test build;
• and
• photocuring volumes of the material via exposure to electromagnetic radiation, according to the exposure intensity value and the exposure duration value characterizing the test build, to form a negative stepped pyramid of the test build;
• wherein accessing the set of test characteristics during the second time period comprises accessing a second set of physical measurements of the set of test builds, the second set of physical measurements representing, for each test build in the set of test builds:
• a set of positive measured dimensions corresponding to positive target dimensions of levels of a positive step pyramid of the test build;
• and
• a set of negative measured dimensions corresponding to negative target dimensions of levels of a negative step pyramid of the test build;
• and
• wherein deriving the set of functions for the material during the second time period comprises deriving a function representing a relationship between the dimensional accuracy characteristic, an exposure intensity parameter and an exposure duration parameter by:
• for each test build in the set of test builds, calculating a measured dimensional accuracy based on the set of positive measured dimensions for the test build and the set of negative measured dimensions for the test build;
• selecting a subset of satisfactory test builds based on the measured dimensional accuracy for each test build in the set of test builds;
• and
• deriving the first function for the material based on the exposure intensity value and the exposure duration value characterizing each test build in the subset of satisfactory test builds.

The method of claim:

• wherein photocuring the first set of test builds during the initial time period comprises photocuring the first set of test builds via a first additive manufacturing device;
• wherein deriving the set of functions for the material relating the subset of part characteristics and the subset of print parameters during the first time period comprises deriving the set of functions for the material via a second additive manufacturing device;
• and
• wherein serving the print file to the additive manufacturing system for execution during fabrication of the instance of the target part during the second time period comprises serving the print file to a third additive manufacturing device.

The method of claim:

• further comprising, during an initial time period preceding the first time period:
• generating a cure characterization test file defining a first set of test builds arranged across a build area, each test build characterized by a total exposure energy value;
• photocuring the first set of test builds by, for each test build, selectively exposing the material to an exposure energy corresponding to the total exposure energy value characterizing the test build;
• accessing a first set of physical measurements representing a depth of cure for each test build;
• calculating a working curve of the material based on the first set of physical measurements;
• for assessing a surface roughness characteristic:
• generating a second test file based on the working curve of the material, the second test file defining the set of test builds, each test build in the set of test builds:
• characterized by an exposure intensity value and an exposure duration value corresponding to a total exposure energy value greater than a target exposure energy of the material;
• and
• defining a horizontal section of a contiguous column;
• and
• photocuring the set of test builds based on the second test file by, for each test build in the set of test builds, photocuring the horizontal section of the contiguous column for the test build via exposure to electromagnetic radiation according to the exposure intensity value and the exposure duration value characterizing the test build;
• wherein accessing the set of test characteristics during the second time period comprises accessing a second set of physical measurements of the set of test builds, the second set of physical measurements representing, for each test build in the set of test builds, a measured surface roughness parameter of the horizontal section of the contiguous column;
• and
• wherein deriving the set of functions for the material during the second time period comprises deriving a function representing a relationship between the surface roughness characteristic, an exposure intensity parameter and an exposure duration parameter by:
• selecting a subset of satisfactory test builds based on the measured surface roughness parameter for each test build in the set of test builds;
• and
• calculating an exposure intensity range for the material based on the exposure intensity value characterizing each test build in the subset of satisfactory test builds.

A method for generating a print file for a target part, the method comprising:

• during a first time period:
• accessing a set of test characteristics representing dimensional properties and mechanical properties of a set of test builds formed of a material;
• accessing a set of test print parameters executed by a set of additive manufacturing systems during fabrication of the set of test builds;
• deriving a set of functions for the material relating a subset of part characteristics and a subset of print parameters based on:
• the set of test characteristics;
• and
• the set of test print parameters;
• and
• storing the set of functions in a material profile associated with the material;
• and
• during a second time period succeeding the first time period:
• accessing a virtual model representing the target part formed of the material;
• for a first part characteristic in a set of part characteristics:
• presenting the first part characteristic to a user via a user interface executing on a computing device accessed by the user;
• and
• receiving a first target value via adjustment of a first slider by the user;
• based on the set of functions:
• calculating a first set of print parameter ranges of a set of print parameters for the target part, limited by the first target value for the first part characteristic;
• and
• calculating a second part characteristic range of a second part characteristic in the set of part characteristics, limited by the first set of print parameter ranges;
• presenting the second part characteristic range of the second part characteristic to the user via the user interface;
• receiving a second target value, for the second part characteristic, within the second part characteristic range via adjustment of a second slider by the user;
• calculating a second set of print parameter ranges of the set of print parameters for the target part, limited by the first target value for the first part characteristic and the second target value for the second part characteristic;
• generating the print file for the target part based on the virtual model of the target part and the second set of print parameter ranges;
• and
• serving the print file to an additive manufacturing system for execution during fabrication of an instance of the target part.

The method of claim:

• further comprising, during an initial time period preceding the first time period:
• accessing a first material property of the material;
• identifying a second material associated with a second material property analogous to the first material property;
• and
• accessing a set of nominal part characteristic ranges associated with the second material from a second material profile in a library of material profiles;
• and
• wherein presenting the second part characteristic during the second time period comprises presenting the second part characteristic, via the user interface, adjacent the second slider by:
• populating a first text box with a nominal lower boundary of a nominal part characteristic range corresponding to the second part characteristic;
• and
• populating a second text box with a nominal upper boundary of the nominal part characteristic range corresponding to the second part characteristic.

The method of claim:

• further comprising, during an initial time period preceding the first time period:
• accessing a subset of functions, in the set of functions, associated with the first part characteristic and the second part characteristic;
• and
• calculating a lower boundary and an upper boundary of the second part characteristic range based on the subset of functions;
• wherein presenting the second part characteristic during the second time period comprises presenting the second part characteristic, via the user interface, adjacent the second slider by:
• populating a first text box with the lower boundary of the second part characteristic range;
• and
• populating a second text box with the second upper boundary of the second part characteristic range;
• and
• further comprising, in response to receiving the first target value, for the first part characteristic:
• recalculating a second lower boundary and a second upper boundary of the second part characteristic based on the set of functions and limited by the first set of print parameter ranges;
• populating a first text box with the second lower boundary of the second part characteristic range;
• and
• populating a second text box with the second upper boundary of the second part characteristic range.

The method of claim:

• wherein receiving the first target value during the second time period comprises receiving a target dimensional accuracy value corresponding to a dimensional accuracy characteristic from the user via the user interface;
• wherein receiving the second target value during the second time period comprises receiving a target part strength value corresponding to a part strength characteristic adjustment of the second slider by the user;
• and
• wherein calculating the second set of print parameter ranges during the second time period comprises calculating an exposure duration range for an exposure duration parameter based on a function representing a relationship between the dimensional accuracy characteristic and the exposure duration parameter and limited by the target dimensional accuracy value and the target part strength value.

A method for generating a print file for a target part, the method comprising:

• during a first time period:
• accessing a set of test characteristics of a set of test builds formed of a material;
• accessing a set of test print parameters executed during fabrication of the set of test builds;
• deriving a set of functions for the material relating a subset of part characteristics and a subset of print parameters based on:
• the set of test characteristics;
• and
• the set of test print parameters;
• and
• storing the set of functions in a material profile associated with the material;
• and
• during a second time period succeeding the first time period:
• accessing a virtual model representing the target part formed of the material;
• for a first part characteristic in a set of part characteristics, receiving a first target value from a user via a user interface;
• based on the set of functions, calculating a first set of print parameter ranges of a set of print parameters for the target part, limited by the first target value for the first part characteristic;
• generating the print file for the target part based on the virtual model of the target part and the first set of print parameter ranges;
• and
• serving the print file to an additive manufacturing system for execution during fabrication of an instance of the target part.