• 专利附录
  • 专利说明
  • 权利要求
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    • 专利摘要:
    A system and a method for calculating recoating parameters for forming an object in an environment of additive manufacturing are provided. Various embodiments are associated with determining one or more parameters of a given layer of a shaped object, including the removal of the object. One or more recoating parameters are determined based on the determined low parameters. The one or more recoating parameters are used to control the deposition of building material or recoating a layer of the formed object.
    公开号:BE1022945B1
    申请号:E2015/5608
    申请日:2015-10-02
    公开日:2016-10-20
    发明作者:Sam Coeck
    申请人:Materialise N.V.；
    IPC主号:
    专利说明:

    System and method for re-coating in an environment of additive manufacturing
    Background of the Invention Field of application of the invention
    The invention relates to the re-coating of a new layer of building material in an additive manufacturing environment. More specifically, the application relates to a system and method for automatically determining recoating parameters for an object formed in an additive manufacturing environment.
    Description of the technology involved
    In the domain of additive manufacturing, three-dimensional fixed objects are formed on the basis of a digital model. Since the manufactured objects are three-dimensional, additive manufacturing is also commonly referred to as three-dimensional ("3D") printing. One type of a sound additive manufacturing technique is called stereo lithography. These techniques can direct a light source (e.g., UV, IR, laser beam, etc.) to a specific location for the purpose of polymerizing or hardening layers of building materials used to create the desired three-dimensional ("3D") object. The three-dimensional object is formed layer after layer by hardening the layers of building material.
    For each layer of the object to be formed, a new layer of building material is coated on the forming platform. Accordingly, after a layer of the object has been formed, the platform is recoated with the building material for the next layer of the object to be formed. Numerous errors can occur in the course of this recoating process, which can cause the entire formation process of the object to fail. In the recoating process, for example, too much or too little building material can be applied to the platform. Against the background of these and other problems identified by the inventor, there is a need for systems and methods to improve the recoating process.
    Summary
    In one embodiment, a system is provided for calculating recoating parameters in an additive manufacturing environment. The system contains a memory and a processor. The processor is configured with a view to determining one or more layer parameters for a first layer of an object. The processor is further configured for calculating one or more re-coating parameters for a second layer of the object based on the determined one or more layer parameters, the second layer being formed after the first layer. The processor is further configured with a view to controlling the deposition of building material on a forming zone of an additive manufacturing device based on the calculated one or more recoating parameters.
    In another embodiment, a method is provided for calculating recoating parameters in an additive manufacturing environment. The method comprises determining one or more layer parameters for a first layer of an object. The method further comprises calculating one or more recoating parameters for a second layer of the object based on the determined one or more layer parameters, the second layer being formed after the first layer. The method further comprises checking the deposition of building material on a formation zone of an additive manufacturing device based on the calculated one or more recoating parameters.
    In yet another embodiment, a permanently computer-readable medium is provided which, when executed on a computer, performs a method for calculating recoating parameters in an additive manufacturing environment. The method comprises determining one or more layer parameters for a first layer of an object. The method further comprises calculating one or more recoating parameters for a second layer of the object based on the determined one or more layer parameters, the second layer being formed after the first layer. The method further comprises checking the depositing of building material on a formation zone of an additive manufacturing device based on the calculated one or more recoating parameters.
    Brief description of the drawings
    Figure 1 is an example of a system for designing and producing three-dimensional objects.
    Figure 2 illustrates a functional block diagram of one example of the computer of Figure 1.
    Figure 3 illustrates an advanced process for the production of a three-dimensional object.
    Figure 4A is an example of an additive manufacturing device that can calculate re-coating parameters and control re-coating by means of systems and methods described in this text.
    Figure 4B is an example of components of the additive manufacturing device of Figure 4A.
    Figure 4C is another example of an additive manufacturing device that can calculate re-coating parameters and control re-coating by means of systems and methods described in this text.
    Figure 5 is a plan view of an object being formed on a forming zone of the additive manufacturing device of Figure 4A.
    Figure 6 is a flowchart illustrating one example of a process for forming an object by means of systems and methods for automatically calculating recoating parameters.
    Detailed description of certain embodiments of the invention
    Systems and methods described in this text provide an improved possibility for re-coating a new layer in an additive manufacturing environment as an element of a forming process. One problem with some re-coating processes is that one set of re-coating parameters is chosen for all courses. Accordingly, the amount of building material added in the recoating process may not be suitably based on the recoating parameters, which may result in the formation failing and / or taking more time.
    Some systems and methods for re-coating result in an unsuitable (i.e. too high or too low) amount of building material being added by fully immersing the forming platform in the building material and then scraping off the excess building material. Other systems and methods may use a combination of a system of depositing a layer of building material on the previously formed layer using a recoating knife, eliminating the complete immersion of the forming platform, and scraping off the excess building material. However, these solutions are far from ideal.
    Instead, the systems and methods described in this text allow recoating parameters to be calculated automatically, in a number of embodiments, layer after layer, for the forming process of each object. Such systems and methods can, for example, reduce the amount of building material used, shorten the forming time, and / or produce better quality objects.
    Embodiments of this invention can be used in a system for designing and producing three-dimensional objects. With reference to Figure 1, an example is illustrated of a computer environment suitable for implementing a system of design and production of a three-dimensional object. This environment contains a system 100. The system contains one or more computers 102a-102d which can take various forms, such as, for example, any workstation, any server, or any other computer device that can process information. In a number of aspects, each of the computers 102a-102d can be connected by any suitable communication technology (e.g., an internet protocol) to a network 105 (e.g., the internet). Accordingly, the computers 102a-102d can mutually transmit and receive information (e.g., software, digital representations of three-dimensional objects, commands or instructions to operate an additive manufacturing device, etc.) via the network 105.
    The system 100 further comprises one or more additive manufacturing devices (e.g. 3D printers) 106a-106b. As illustrated, the device of additive manufacturing 106a is directly connected to a computer 102d (and through the computer 102d connected to the computers 102a-102c via the network 105), and the device of additive manufacturing 106b is directly connected to the computer computers 102a-102d via the network 105. Those skilled in the art will therefore understand that a device of additive manufacturing 106 can be directly connected to a computer 102, can be connected to a computer 102 by means of a network 105, and / or can be connected to a computer 102 via another computer 102 and through the network 105.
    It should be noted that although the system 100 has been described with regard to a network and one or more computers, the techniques described in this text also apply to a single computer 102 that may be directly connected to device of additive manufacturing 106.
    Figure 2 illustrates a functional block diagram of one example of the computer of Figure 1. The computer 102a includes a processor 210 in data communication with a memory 220, an input device 230 and an output device 240. In a number of embodiments, the processor is furthermore in data communication with a optional network interface card 260. Although described as a separate component, it should be understood that the functional blocks described with respect to computer 102a should not be different structural elements. By way of example, the processor 210 and the memory 220 can be included in a single chip or a single board.
    The processor 210 may be a universal processor or a digital signal processor (digital signal processor, DSP), an application specific integrated circuit (application specific integrated circuit, ASIC), a field-programmable gate array (field programmable gate array, FPGA) or another programmable logic unit, a separate port or transistor, separate hardware components, or any combination thereof, to perform the functions described in this text. A processor can also be implemented as a combination of computer equipment, for example a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in combination with a DSP core, or any other such configuration.
    The processor 210 can be coupled, via one or more buses, to read information from, or write to, the memory 220. The processor can additionally, or as another possibility, contain memory, e.g. processor registers. The memory 220 may contain processor cache, including a multi-level hierarchical cache in which different levels exhibit different options and different access speeds. This memory 220 may further comprise a random access memory (RAM), as well as other devices with a volatile memory or devices with a non-volatile memory. The data storage can consist of hard disks, optical disks such as compact discs (CDs) or digital video discs (DVDs), flash memory, diskettes, magnetic tape, and Zip drives.
    The processor 210 can also be coupled to an input device 230 and an output device 240 for resp. get input from, and deliver output to, a user of computer 102a. Suitable input devices include, but are not limited to, a keyboard, buttons, keys, switches, pointing devices, a mouse, a joystick, a remote control device, an infrared detector, a voice recognition system, a barcode reader, a scanner, a video camera (possible) coupled with image processing software to detect, for example, hand or face movements, a motion detector, a microphone (possibly linked to sound processing software to detect, for example, voice commands). Suitable output devices include, but are not limited to, visual output devices, including screens and printers, audio output devices, including speakers, headphones, earphones and alarms, additive manufacturing devices, and haptic output devices.
    The processor 210 may further be coupled to a network interface card 260. The network interface card 260 prepares data generated by the processor 210 for transmission via a network in accordance with one or more data transmission protocols. The network interface card 260 also decodes data received over a network in accordance with one or more data transmission protocols. The network interface card 260 can contain a transmitter, a receiver or both a transmitter and a receiver. In other embodiments, the transmitter and the receiver can be two different components. The network interface card 260 can be in the form of a universal processor or a digital signal processor (digital signal processor, DSP), an application-specific integrated circuit (application-specific integrated circuit, ASIC), a field-programmable gate array ( field programmable gate array (FPGA) or another programmable logic unit, a separate gate or transistor, separate hardware components, or any combination thereof to perform the functions described in this text.
    Figure 3 illustrates a process 300 for the production of a three-dimensional object or a three-dimensional device. As illustrated, in a step 305, a digital representation of the object is designed by means of a computer, e.g., the computer 102a. For example, two-dimensional or three-dimensional information can be entered into the computer 102a to assist in designing the digital representation of the three-dimensional object. Moving to a step 310, information is sent from the computer 102a to an additive manufacturing device, e.g., the additive manufacturing device 106, and the device 106 starts the additive manufacturing process in accordance with the received information. In a step 315, the device of additive manufacturing 106 continues the production of the three-dimensional object using suitable materials, for example, a liquid resin.
    These suitable materials can be, but are not limited to, a photopolymer resin, polyurethane, methyl methacrylate-acrylonitrile-butadiene-styrene copolymer, resorbable materials such as polymer-ceramic composites, etc. Examples of commercially available materials are: the materials of the DSM Somos® series 7100, 8100, 9100, 9420, 10100, 11100, 12110, 14120 and 15100 from DSM Somos; Stratasys materials ABSplus-P430, ABSi, ABS-ESD7, ABS-M30, ABS-M30i, PC-ABS, PC-ISO, PC, ULTEM 9085, PPSF and PPSU; the line materials Accura Plastic, DuraForm, CastForm, Laserform and VisiJet from 3-Systems; the PA materials line, PrimeCast and PrimePart materials and Alumide and CarbonMide from EOS GmbH. The VisiJet materials line from 3-Systems can contain Visijet Flex, Visijet Tough, Visijet Clear, Visijet HiTemp, Visijet e-stone, Visijet Black, Visijet Jewel, Visijet FTI, etc. Examples of other materials include Objet materials, such as Objet Fullcure, Objet Veroclear, Objet Digital Materials, Objet Duruswhite, Objet Tangoblack, Objet Tangoplus, Objet Tangoblackplus, etc. Another example of materials is Renshape 5000- and 7800 materials series. Further, in a step 320, the three-dimensional object is generated.
    Figure 4 illustrates an example of an additive manufacturing 400 device for generating a three-dimensional (3D) object. In this example, the device of additive manufacturing 400 is a device of stereolithography. The device of stereolithography 400 contains a reservoir 402 that may contain building material, for example a liquid (such as a resin) that is used to form the three-dimensional object. The device of stereolithography 400 further comprises in a number of embodiments a conveying system 404 that can be used for transporting the liquid from the reservoir 402 to a head coating the object 406. In a number of embodiments the device of stereolithography 400 contains a device coating the object 406 head without a transport system. The object-coating head 406 may include a recoating knife in a number of embodiments. The conveying system may include one or more tubes, pipes or hoses configured for conveying the liquid from the reservoir 402. In a number of embodiments, the conveying system 400 may include metal or plastic materials, such as the DSM Somos® series materials 7100, 8100, 9100, 9420, 10100, 11100, 12110, 14120 and 15100 from DSM Somos; the lines of materials Accura Plastic from 3D-Systems, or any other suitable material.
    The stereolithography device may further exhibit a conductive structure in the reservoir 402, which is configured for guiding a flow of the liquid from the reservoir 402 to the transport system 404. The structure may, for example, be a series of tubes or display plates strategically positioned to direct the flow of fluid to transport system 404. The device 400 may also include a forming zone where the liquid resin is deposited. The forming zone generally includes a support for the forming zone (e.g., forming zone platform) on which the three-dimensional object is formed. While this specific example provides a stereolithography device with a conveying system, those skilled in the art will appreciate that other types of stereolithography devices may not use a conveying system to transfer resin to a forming platform or use additional systems and methods to transfer resin to to bring a training platform. For example, support for the formation zone may be configured to sink into the reservoir during the course of the production process. Accordingly, the forming zone and a three-dimensional object formed thereon can be immersed in the reservoir so as to deposit the liquid resin on the forming zone.
    The device of stereolithography 400 also contains a light source. The light source is usually included for the purpose of polymerizing the liquid to form a three-dimensional object. The light source can take various forms. In a number of embodiments, the light source may be an electromagnetic light source, for example, an ultraviolet light source (UV) or an infrared light source. Generally, the light source can be any type of laser beam with the ability to harden the liquid.
    In some embodiments, the device of stereo lithography 400 may include at least one pump that is used to pump the liquid from the reservoir 402 to the object coating head 406. By way of example, this can be a displacement pump and / or a pump of the centrifugal type. In some embodiments, the pump may include a filter unit to further filter the liquid resin before being deposited on the forming zone. In a number of aspects, the pump can provide a defined flow (e.g. 0.5-40 l / min) that can be fixed or adjusted by means of an active feedback loop. The feedback loop can for example be set based on measurements of the current. As another example, the feedback can be indirect using measurements of the thickness of the layers deposited in the process of additive manufacturing.
    The device of stereolithography 400 can be used for the purpose of generating one or more three-dimensional objects layer after layer. The device of stereolithography 400 may, for example, use a liquid resin (e.g., a photopolymer resin) to create an object layer after layer, such as by depositing the resin from the object coating head 406 in the form of a curtain and / or by immersing the support for the formation zone in the reservoir. In these implementations, the object coating head 406 and / or the support for the forming zone can deposit successive layers of the liquid resin to form the object. Initially, the object coating head 406 and / or the support for the forming zone can deposit (e.g., coat) successive layers of the liquid resin to form the object on the support for the forming zone. Subsequent layers can then be deposited (e.g., re-coated) on the previous layer after forming the dimensions of the three-dimensional object for the previous layer.
    Upon depositing each layer, the light source, which can be controlled by a computer as described above, can follow a specific pattern on the surface of the liquid resin to thereby form the dimensions of the three-dimensional object for that layer. The exposure to the light source polymerizes or hardens the pattern followed on the resin and attaches it to the layer beneath it. After a layer has been polymerized, a new layer of liquid material is deposited (e.g., re-coated) on the forming zone, for example, the support for the forming zone can be reduced by the thickness of a single layer and / or the 406 resin-coating head can deposit resin, and a new layer pattern is followed and attached to the previous layer. The forming process is complete when the three-dimensional object is formed by depositing all layers of the three-dimensional object.
    As described above, the deposition of layers or the re-coating of the building material can be carried out in accordance with certain re-coating parameters. Systems and methods described in this text allow recoating parameters to be calculated automatically, in a number of embodiments layer by layer, for the forming process of each object. The calculation and use of such re-coating parameters is described in more detail in what follows, with regard to an additive manufacturing device 400 described as a stereolithography machine 400. However, those skilled in the art understand that the systems and methods described may also be used with other suitable devices of additive manufacturing.
    Figure 4C is another preferred embodiment of the stereo lithography machine 400. As illustrated, the stereolithography machine 400 in this embodiment includes a reservoir 402 for storing liquid building material, e.g., resin or other materials as previously described with reference to Figure 4A. Furthermore, the machine 400 includes a head 406 coating the object such as that described above with reference to Figure 4A. Head 406 re-coating the object may contain a recoating knife, for example a doctor blade. In a number of embodiments, the object-recoatable head 406 can be configured with a view to depositing liquid building material on the forming zone of the machine 400 as described above. By way of example, the object-recoatable head 406 can be configured with a view to withdrawing building material from the reservoir 402 and depositing it on the forming zone, for example by means of a vacuum pump and tubes connecting the object-recoatable head 406 to the reservoir 402.
    As described above, the machine 400 includes a support for the forming zone (e.g., forming zone platform) on which the three-dimensional object is formed. In this embodiment, the support for the formation zone is configured to sink into the reservoir during the course of the production process. Accordingly, the forming zone and a three-dimensional object formed thereon can be immersed in the reservoir so as to deposit the liquid resin on the forming zone.
    The device of stereolithography 400 also contains a light source. The light source is usually included for the purpose of polymerizing the liquid to form a three-dimensional object. The light source can take various forms. In a number of embodiments, the light source may be an electromagnetic light source, for example, an ultraviolet light source (UV) or an infrared light source. Generally, the light source can be any type of laser beam with the ability to harden the liquid.
    In a number of embodiments, the recoating parameters may be calculated by a control computer as illustrated in Figure 4B, which may include one or more computers. The control computer 434 may be one or more of the computer 102 (a) of Figure 2 and the computer 305 of Figure 3. Alternatively or additionally, the control computer 434 may be a separate computer configured for control purposes of the recoating process. The control computer 434 may interface with the device of additive manufacturing 400. The control computer 434 may further comprise software configured for calculating recoating parameters and which, directly or indirectly (by adjusting parameters read by an individual controller) control the deposition of layers or the re-coating of layers by the establishment of additive manufacturing 400. For example, the control computer 434 may directly or indirectly control the conveying system 404, the object coating head 406 and / or the support for the forming zone.
    In a number of embodiments, the recoating parameters that can be calculated by a control computer 434 may include one or more of: whether a deep immersion is to be performed (e.g., immersion of the support for the forming zone in the building material), a depth of the deep immersion ( for example the depth that the support for the forming zone is immersed in the building material), a time of deep immersion (for example the time that the support for the forming zone is immersed in the building material), a knife gap (for example the vertical separation distance between the bottom of the object coating head 406 and the top of the previous (hardened) layer, a pre-swing time (e.g., the time between hardening of the previous layer and when the object coating head 406 starts to swing across the forming zone to deposit building material ), a sweeping speed (e.g., the speed at which the head 4 coating the object 06 moves across the forming zone to swing off building material), a number of turns (e.g., the number of times that the object 406 covers or moves across the forming zone and deposits per layer of building material), and a wait after immersing ( for example, the time between immersion of the support for the forming zone and when the forming (e.g. depositing and hardening) of the next layer begins).
    The recoating parameters can be calculated automatically based on a "removal" value calculated for that object. The removal is defined in this text as the maximum distance between a location within the layer perimeter and that perimeter. In other words, the removal can be defined as the maximum value of all distances between each point of a certain layer on the formed object and the closest building material (i.e. the shortest distance to any part of the building material). Figure 5 illustrates by way of example a plan view of a cured layer 515 of an object formed in a forming zone 505. The uncured building material 510 surrounds the layer 515 and is also located in an inner zone in the layer 515. Each of the points 520 525, 540 and 550 are points of the layer 515 on the formed object. As illustrated, the layer 515 is divided into sections 560 and 565 that are different for layer 515 (although the general object may then not be connected on a different layer). Such separate parts in a layer can be called "islands".
    The shortest distance between the point 540 and the building material 510 is indicated by the dashed line 542. The shortest distance between the point 540 and the building material 510 is the same in two directions and is represented by the distances 530 and 532. The shortest distance between the point 525 and the building material 510 are the same in two directions and are represented by the distances 534 and 536. The shortest distance between the point 550 and the building material 510 is the same in many directions and one such direction is represented by the distance 532. The distances 530, 532, 534, and 536 are the same as illustrated, and all are the maximum value of the shortest distance between any point on the layer 515 and any portion of the building material 510. Consequently, the removal of the layer 515 of the object is the value of distance 530, the same as distances 532, 524, and 536.
    For a shaped object, the removal can be calculated layer after layer. In a number of embodiments, the control computer 434 may attempt to calculate the actual removal of a layer of the object by, for example, calculating the shortest distance between each point on the layer of the object and any portion of the building material, by way of example using a brute force approach. However, calculating such distances for each point on the layer of the object may prove impossible because it is too complex for the computer. Accordingly, in a number of embodiments, the control computer 434 can calculate an estimate of the removal of a layer from the object, for example using a Monte-Carlow method or any other similar sampling of random, pseudo-random or other samples. The control computer 434 may, for example, randomly select a number of points on the layer of the object and calculate the shortest distance between each selected point and any portion of the building material. The control computer 434 can select the maximum of the calculated shortest distances as the removal value.
    Zones of the object with a lower removal value can be easier to re-coat because the building material will reach the zone more easily and surplus building material can be led away more easily. Zones of the object with a higher removal value may be more difficult to re-coat because they are further away from the building material and surplus building material can be more difficult to divert. Accordingly, the recoating parameters can be adjusted based on the removal of the object and in some embodiments on the removal of a given layer from the object. In particular, the removal of a given layer (e.g., layer n) from a forming process can be used to determine the recoating parameters for the next layer (layer n + 1).
    In a number of embodiments, the control computer 434 can automatically calculate the recoating parameters based on the removal as described above (which can be considered as an example of a layer parameter) and some additional layer parameter including one or more of the following: a direction of recoating for a given layer, identification of trapped volumes in the formed object, and a critical zone time equal to the time that the object coating head 406 moves after having passed a "critical zone." For example, the direction in which the re-coating may be performed ( for example, the direction in which the object coating head 406 moves when depositing a layer of building material) influences which areas of the object can be most easily re-coated, for example, surfaces or areas of the object in the opposite direction to the direction of recoating (e.g. at the direction of which the re-coat moving away) are easier to re-coat. As one example, in the case of a circular surface of the object, the removal can generally be equal to the radius of the circle. However, when the re-coating moves in a specific direction, for example, from left to right across the circular surface, the zones to the right of the center of the circle may be more difficult to re-coat, and therefore the re-coating parameters may be adjusted with a view to re-coating such zones. In addition, the object may contain "enclosed volumes", or zones in the object from which the building material does not easily drain since the object completely encloses the building material.
    A critical zone can be a "locally removed" point or zone. For example, as described above, a layer of an object can show an absolute removal value based on one or more points equal to the maximum distance of any portion of However, the layer may also have points not equal to the maximum distance of the building material for the entire layer, but rather the maximum distance for a specific zone of the layer, for example for an island. for example, not be the point of the general layer 515 that is furthest away from the building material, but may be the point furthest away from the building material for the island 560. Accordingly, point 550 may be a locally removed point on island 560 and points 520 and 525 may be locally removed points on the island 565. In a number of embodiments, such critical zones may be passed through the control computer 43 4 are calculated. In a number of embodiments, the critical zones can be calculated on an island-by-island basis. Taking into account such critical zones can help to reduce the waiting time after immersion, for example by reducing a plurality of these times each associated with a given island. For example, the counter for the waiting time after the immersion may begin to count down for each island when the recoater has passed the critical zone, rather than when the entire platform has been re-coated. The last counter of the multitude of counters that comes to zero can determine the total waiting time after the immersion. It should be noted that in a number of embodiments, multiple physical counters for counting down are not required for each island, and instead the total waiting time after immersing can be calculated based on a known recoating rate to the actual waiting time after immersing for determine the entire process.
    In a number of embodiments, the control computer 434 can automatically calculate the recoating parameters based on the removal as described above, optionally one or more layer parameters as described above, and one or more machine parameters of the additive manufacturing device, including the following: a type of the recoating mechanism (e.g., conveying system 404 and the object coating head 406, the support for the forming zone, etc.) to re-coat the forming zone, a type of building material used, and a layer thickness produced by the additive manufacturing 400 device.
    As described above, certain parameters of a layer can make the object easier to re-coat (for example, a lower removal value, etc.) and certain parameters of a layer can make the object difficult to re-coat (for example, a higher removal value, etc.). At least in part based on one or more of these layer parameters and optionally one or more of the machine parameters described above, the control computer 434 can calculate recoating parameters. The easier it is to re-coat an object, for example, can influence one or more of the re-coating parameters as follows: a depth and / or time of the deep immersion can be reduced or the deep immersion completely eliminated, a knife gap can be increased, a pre-blow time can be increased reduced, a sweep speed can be increased, a number of sweeps can be reduced, a waiting time after immersing can be reduced. Similarly, the harder it is to re-coat an object, for example, one or more of the recoating parameters can be affected as follows: a depth and / or time of deep immersion can be increased, a knife gap can be lowered, a pre-blow time can be increased, a sweep speed can be reduced, a number of sweeps can be increased, and a wait time after immersing can be increased.
    In a number of embodiments, the control computer 434 calculates recoating parameters at least in part based on well-defined threshold values for one or more of the layer parameters. These well-defined threshold values can be empirically determined and stored in the control computer 434.
    In a number of embodiments, each of the re-coating parameters can be associated with one or more well-defined threshold values unique to the re-coating parameter. In a number of embodiments, a set of the plurality of re-coating parameters may be associated with one or more well-defined threshold values unique to the plurality of re-coating parameters.
    For example, in a number of embodiments, a single immersion threshold value (e.g., 2 mm) may be associated with whether or not the immersion is performed. If the removal is below the immersion threshold, a deep immersion may not be performed. If the removal is above the immersion threshold, a deep immersion may be performed. Furthermore, in a number of embodiments, the immersion threshold can be set with the set of whether or not the deep immersion is performed and the depth of the deep immersion. In such embodiments, the depth of the deep immersion can additionally be determined at a value (e.g., 2 mm) if the removal is above the immersion threshold, and not if the removal is below the immersion threshold.
    In a number of embodiments, there may be multiple threshold values for a recoating parameter or a set of recoating parameters. Accordingly, there can be multiple threshold values on multiple values for a given layer parameter, for example, a first threshold value and a second threshold value greater than the first threshold value. If the layer parameter is smaller than the first threshold value, the recoating parameter (s) can be set to a first value or a set of values. If the layer parameter is larger than the first threshold value and smaller than the second threshold value, the recoating parameter (s) can be set to a second value or a set of values. If the layer parameter is greater than the second threshold value, the recoating parameter (s) can be set to a third value or a set of values.
    For example, in one embodiment, if the removal is less than the first threshold value, the recoating parameters can be set as follows: no deep immersion is performed, the number of sweeps is set to 1, and the wait time after immersing is set to 0. If the removal is greater than the first threshold value and smaller than the second threshold value, the recoating parameters can be set as follows: the depth of the deep immersion is set to 5 mm, the time of the deep immersion is set to 5 seconds, the swing speed is set on slow, the number of sweeps is a positive integer N (for example 1), and the waiting time after immersion is set to 15 sec. If the removal is greater than the second threshold value, the recoating parameters can be set as follows: the depth of the deep immersion is set to 10 mm, the time of the deep immersion is set to 10 seconds, the swing speed is set to slow the number of sweeps is a positive integer greater than N (e.g., 3), and the wait time after immersion is set to 15 sec.
    In another embodiment, the removal R of a layer can determine the recoating parameters as follows: the set of the recoating parameters immersion depth, immersion time, and pre-blow time can be associated with a first removal threshold (e.g., 50 mm, where if R <50, immersion depth = 0 , immersion time = 0, and pre-swing time = 0, and if R> 50, immersion depth = 5 mm, immersion time = 5 sec, and pre-swing time = 5 sec, the number of sweeps can be associated with a second removal threshold (for example, 75 mm, where if R <75, number of turns = 1, and if R> 75, number of turns = 3), the swing speed is based on a third, fourth and fifth removal threshold (for example 2, 10 and 15 mm respectively, where if R <2, the number sweeps = 20), 2 <R <10, number of sweeps = 15; 10 <R <15, number of sweeps = 12; R> 15, number of sweeps = 10) or sweeping speed is based on a (eg example ceiling (70 / (R + 4) + 7.5)); and the waiting time after immersion is based on another formula (for example, min (ceiling (R / 3), 15).
    Figure 6 is a flowchart illustrating one example of a process for forming an object by means of the systems and methods for automatically calculating recoating parameters as described above. The process starts at block 602, where an initial layer of building material is deposited on the forming zone of the additive manufacturing 400 device by the control computer 434 which controls the conveying system 404, the object coating head 406 and / or the support for the forming zone to to dispose of building material. The initial layer of building material can be deposited using a first set of recoating parameters, either specifically calculated for the initial layer, or based on a removal value 0. The process continues on a block 604, where the control computer 434 checks the light source to find a pattern. follow the surface of the building material to harden the building material and form the dimensions of the object for the current layer.
    Furthermore, the control computer 434 on a block 606 determines whether an additional layer of the object is to be formed. If at block 606 the control computer 434 determines that no additional layer of the object is to be formed, the process ends. If the control computer 434 determines that an additional layer of the object is to be formed, the process proceeds to a block 6087.
    At block 608, the control computer 434 automatically calculates one or more recoating parameters. As described above, the control computer 434 may calculate the one or more recoating parameters based on one or more layer parameters, including deletion, for the current layer formed at block 604. Further, in some embodiments, the control computer 434 may be the one or more also calculate multiple re-coating parameters based on one or more of the machine parameters. Further, on a block 610, the control computer 434 checks the transport system 406, the object coating head 608 and / or the support for the forming zone to deposit another layer of building material based on the one or more recoating parameters calculated on block 608 for the current layer. The process then proceeds to block 604.
    Various embodiments described in this text provide for the use of a computer control system. Those skilled in the art understand that these embodiments can be implemented using different types of computer devices, including computer environments or configurations for general use and / or computer environments or configurations for specific purposes. Examples of known computer systems, environments and / or configurations that may be suitable for use in combination with the embodiments described above are, but are not limited to, personal computers, server computers, handhelds or laptops, multiprocessor systems, on microprocessor-based systems, programmable consumer electronics, network PCs, mini-computers, mainframe computers, decentralized computer environments with any of the aforementioned systems or devices, etc. These devices may contain stored instructions that, if executed on a microprocessor in the computer device, cause the computer device to perform specified actions for the purpose of executing the instructions. As used in this text, "instructions" refers to computer-implemented steps for processing information in the system. Instructions may be implemented in software, firmware, or hardware and may include any type of programmed steps taken by components of the system.
    A microprocessor can be any conventional microprocessor with one or more chips, such as a Pentium® processor, a Pentium® pro processor, an 8051 processor, an MIPS® processor, a Power PC® processor, or an Alpha® processor. The microprocessor may also be any conventional special purpose microprocessor, for example a digital signal processor or a graphic processor.
    The microprocessor generally includes conventional address lines, conventional data lines, and one or more conventional control lines.
    Aspects and embodiments of the invention described in this text can be implemented in the form of a method, a device, a manufactured article, using standard programming or engineering techniques to produce software, firmware, hardware or any combination thereof . The term "produced item" as used herein refers to code or logic implemented in hardware or permanent computer-readable media such as optical disks, and volatile or non-volatile memory devices or temporary computer-readable media such as signals, carriers, etc. Such hardware may include, but is not limited to, field-programmable gate arrays (field-programmable gate arrays, FPGAs), application-specific integrated circuits (application-specific integrated circuits, ASICs), complex programmable logic chips (complex programmable logic devices (CPLDs), programmable logic arrays (programmable logic arrays, PLAs), microprocessors, or other similar processing devices.
    FIG. 1__
    COMPUTER COMPUTER
    FIG. 2_
    FIG. 4B
    FIG. 6
    权利要求:
    Claims (25)
    [1]
    CONCLUSIONS
    A system for calculating recoating parameters in an additive manufacturing environment, comprising: - a memory; and - a processor configured for the purpose of: - determining one or more layer parameters for a first layer of an object; - calculating one or more recoating parameters for a second layer of the object based on the determined one or more layer parameters, the second layer being formed after the first layer; and - checking the deposition of building material on a formation zone of an additive manufacturing facility on the basis of the calculated one or more recoating parameters.
    [2]
    The system of claim 1, wherein the one or more layer parameters include removal.
    [3]
    The system of claim 2, wherein removal includes a maximum value of distances between one or more points and a closest portion of the building material.
    [4]
    The system of claim 3, wherein the processor is further configured to randomly select the one or more points.
    [5]
    The system of claim 2, wherein the one or more layer parameters include one or more of a direction of re-coating, an identification of embedded volumes, and a critical zone time.
    [6]
    The system of claim 1, further comprising a light source for the purpose of curing the building material, and wherein the processor is further configured for checking the light source.
    [7]
    The system of claim 1, further comprising at least one of a support for the forming zone and a head coating the object configured for depositing the building material on the forming zone, the processor being further configured for the purpose of forming checking at least one of the support for the formation zone and the head coating the object.
    [8]
    The system of claim 1, wherein the one or more recoating parameters include one or more of a depth of deep immersion, or a deep immersion is to be performed, a time of deep immersion, a knife gap, a pre-swing time, a swing speed, a number of sweeps, and a wait after immersing.
    [9]
    The system of claim 1, wherein the processor is further configured with a view to calculating one or more recoating parameters based on the determined one or more machine parameters of the additive manufacturing device.
    [10]
    The system of claim 9, wherein the one or more machine parameters include one or more of a type of recoating mechanism, a type of building material, and a thickness of layers produced.
    [11]
    The system of claim 1, wherein the processor is further configured for calculating one or more recoating parameters based on the comparison of the one or more layer parameters with one or more well-defined threshold values.
    [12]
    The system of claim 1, wherein the plurality of the one or more recoating parameters is associated with one of the one or more well-defined threshold values.
    [13]
    A method for calculating recoating parameters in an additive manufacturing environment, comprising: - determining one or more layer parameters for a first layer of an object; - calculating one or more recoating parameters for a second layer of the object based on the determined one or more layer parameters, the second layer being formed after the first layer; and - checking the deposition of building material on a formation zone of an additive manufacturing facility on the basis of the calculated one or more recoating parameters.
    [14]
    The method of claim 12, wherein the one or more layer parameters include removal.
    [15]
    The method of claim 14, wherein removal includes a maximum value of distances between one or more points and a closest portion of the building material.
    [16]
    The method of claim 15, further comprising randomly selecting the one or more points.
    [17]
    The method of claim 14, wherein the one or more layer parameters include one or more of a direction of re-coating, an identification of embedded volumes, and a critical zone time.
    [18]
    The method of claim 13, further comprising curing the building material by means of a light source.
    [19]
    The method of claim 13, further comprising depositing the building material on the forming zone by means of at least one of a support for the forming zone and a head coating the object.
    [20]
    The method of claim 13, wherein the one or more recoating parameters include one or more of a depth of deep immersion, or a deep immersion is to be performed, a time of deep immersion, a knife gap, a pre-swing time, a sweep speed, a number of sweeps, and a wait after immersing.
    [21]
    The method of claim 13, further comprising calculating one or more re-coating parameters based on one or more machine parameters of the additive manufacturing device.
    [22]
    The method of claim 21, wherein the one or more machine parameters include one or more of a type of recoating mechanism, a type of building material, and a thickness of layers produced.
    [23]
    The method of claim 13, further comprising calculating one or more recoating parameters based on the comparison of the one or more layer parameters with the one or more well-defined threshold values.
    [24]
    The method of claim 13, wherein the plurality of the one or more recoating parameters is associated with one of the one or more well-defined threshold values.
    [25]
    25. A permanently computer-readable medium which, when executed on a computer, performs a method for calculating recoating parameters in an additive manufacturing environment, which method comprises: - determining one or more layer parameters for a first layer of an object; - calculating one or more recoating parameters for a second layer of the object based on the determined one or more layer parameters, the second layer being formed after the first layer; and - checking the deposition of building material on a formation zone of an additive manufacturing facility on the basis of the calculated one or more recoating parameters.
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    法律状态:
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    US62/060,751|2014-10-07|
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