Image-based monitoring and feedback system for three-dimensional printing

• US 10,265,911 B1
• Filed: 04/25/2016
• Issued: 04/23/2019
• Est. Priority Date: 05/13/2015
• Status: Active Grant

• Current Assignee: Marvell Asia Pte Limited (Marvell Technology Group Limited)
• Original Assignee: Marvell International Limited (Marvell Technology Group Limited)
• Inventors: Capri, Sandra, Asbury, Raymond C.
• Primary Examiner(s): Patel, Ramesh B
• Application Number:
  US15/137,815
• Time in Patent Office: 1,093 Days
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 19/41875 characterised by quality surveillance of production
• CPC Class Codes: G05B 2219/32182 If state of tool, product deviates from standard, adjust system, feedback
• CPC Class Codes: G05B 2219/35134 3-D cad-cam
• CPC Class Codes: G05B 2219/49007 Making, forming 3-D object, model, surface
• CPC Class Codes: G06T 2207/30144 Printing quality
• CPC Class Codes: G06T 2207/30164 Workpiece; Machine component
• CPC Class Codes: G06T 7/001 using an image reference approach
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

The present disclosure describes apparatuses and techniques for using an image-based monitoring and feedback system for three-dimensional printing. In some aspects, a camera captures images of objects being printed and an image-processing system compares the images with benchmark images to detect and correct differences between the object and the benchmark. The correction can be in real time or applied to subsequent printing. Other aspects include a calibration system that prints predefined test objects and compares them to benchmarks to ensure that the printer operating parameters are properly set. The comparison can be manually performed by a user or automated as a part of the image-processing system.

Claims

1. A system for improving print quality of a three-dimensional (3D) printer, comprising:

a camera configured to capture an image of an object being printed by the 3D printer while the object is being printed; and

an image processing system comprising;

a processor; and

a computer-readable media device embodying computer-executable instructions that, when executed by the processor, implement an image-comparison module configured to perform operations comprising;

receiving, from the camera while the 3D printer is printing, the image of the object being printed by the 3D printer;

comparing the image to a benchmark image, the benchmark image being an image that accurately represents the object being printed;

identifying a difference between an element of the object and an analogous element of the benchmark image;

determining an operating parameter of the 3D printer related to the difference; and

sending a control signal to the 3D printer, the control signal effective to adjust the operating parameter of the 3D printer while the 3D printer is printing, the adjustment effective to reduce the difference between the element of the object and the analogous element of the benchmark image.

2. The system of claim 1, wherein sending the control signal to adjust the operating parameter of the 3D printer while the 3D printer is printing is effective to decrease the difference between the element of the object and the analogous element of the benchmark image in subsequent instances of printing the object.

3. The system of claim 2, wherein the operating parameter is one or more selected from the group of:

a distance between a printing nozzle of the 3D printer and a base plate of the 3D printer;

a distance between the printing nozzle of the 3D printer and a surface of a previously printed layer of the object being printed;

a velocity of the printing nozzle of the 3D printer;

a vertical position of the base plate of the 3D printer;

a temperature of the printing nozzle of the 3D printer;

a temperature of a material being extruded from the printing nozzle of the 3D printer;

a temperature of the base plate of the 3D printer; and

a rate of extrusion from the printing nozzle of the 3D printer.

4. The system of claim 2, wherein the operating parameter is a location of the printing nozzle of the 3D printer as an X-Y coordinate location with reference to a plane represented by the base plate of the 3D printer.

5. The system of claim 1, wherein the image-comparison module is further configured to perform operations comprising:

responsive to adjusting the operating parameter of the 3D printer while the 3D printer is printing, the adjustment effective to decrease the difference between the element of the object and the analogous element of the benchmark image, identifying a value of the adjusted parameter;

associating the value of the adjusted parameter with the difference;

storing the value of the adjusted parameter associated with the difference; and

responsive to determining a subsequent difference between the element of the object and the analogous element of the benchmark image, using the associated value to adjust the parameter.

6. The system of claim 1, wherein the image-comparison module is further configured to perform operations comprising:

receiving, from the camera while the 3D printer is printing, another image of the object being printed by the 3D printer;

comparing the other image to the benchmark image;

determining another difference between the element of the object and the analogous element of the benchmark image;

determining that the other difference exceeds a threshold;

responsive to determining that the other difference exceeds the threshold, sending a first control signal to the 3D printer, the first control signal effective to cause the 3D printer to pause printing the object; and

responsive to sending the first control signal, sending a second control signal, the second control signal effective to cause the 3D printer to display an error message.

7. The system of claim 6, wherein the image process system includes a communication interface and the image-comparison module is further configured to perform operations comprising responsive to sending the first control signal, sending an error message to a mobile device, via the communication interface.

8. The system of claim 1, further comprising a sensor, and wherein the operations further comprise:

receiving, from the sensor while the 3D printer is printing, an input value related to a print quality characteristic of the object;

comparing the input value to a benchmark value;

measuring a difference between the input value and the benchmark value;

identifying another operating parameter of the 3D printer related to the difference between the input value and the benchmark value; and

sending another control signal to the 3D printer, the other control signal effective to adjust the other operating parameter of the 3D printer while the 3D printer is printing.

9. The system of claim 8, wherein the sensor is a force transducer, a temperature sensor, or a SONAR detector array.

10. The system of claim 1, wherein the 3D printer further comprises a test target having one or more visual characteristics that are known to the image processing system, and wherein the operations further comprise:

receiving, from the camera, an image of the test target;

analyzing the image to determine the visual characteristics of the test target as represented in the image;

comparing the visual characteristics of the test target as represented in the image to the known visual characteristics of the test target; and

adjusting operating parameters of the camera effective to match the visual characteristics of the test target, as represented in the image, to the known visual characteristics.

11. The system of claim 10, wherein the known visual characteristic of the test target is one or more of a shape, a color, a size, or a distance from the camera.

12. A method for improving print quality of a three-dimensional (3D) printer, comprising:

receiving, from a camera communicatively connected to the 3D printer and while the 3D printer is printing, an image of an object being printed by the 3D printer;

comparing the image to a benchmark image, the benchmark image being an image that accurately represents the object being printed;

identifying a difference between an element of the object and an analogous element of the benchmark image;

determining an operating parameter of the 3D printer related to the difference; and

sending a control signal to the 3D printer, the control signal effective to adjust the operating parameter of the 3D printer while the 3D printer is printing, the adjustment effective to reduce the difference between the element of the object and the analogous element of the benchmark image.

13. The method of claim 12, further comprising sending the operating parameter to the 3D printer, effective to enable the 3D printer to determine a control signal to adjust the operating parameter effective to decrease the difference between the element of the object and the analogous element of the benchmark image in subsequent printing operations.

14. The method of claim 13, wherein sending the operating parameter to the 3D printer, effective to enable the 3D printer to determine a control signal to adjust the operating parameter effective to decrease the difference between the element of the object and the analogous element of the benchmark image in subsequent printing operations further comprises determining the control signal by:

identifying a previously stored value of the parameter associated with the difference, the previously stored value having been adjusted to decrease the difference in a previous printing operation; and

using the previously stored value to adjust the operating parameter.

15. The method of claim 12, further comprising sending a control signal to the 3D printer, the control signal causing the 3D printer to adjust the operating parameter effective to decrease the difference between the element of the object and the analogous element of the benchmark image in subsequent printing operations.

16. The method of claim 15, wherein sending a control signal to the 3D printer, the control signal causing the 3D printer to adjust the operating parameter effective to decrease the difference between the element of the object and the analogous element of the benchmark image in subsequent printing operations further comprises:

responsive to adjusting the operating parameter of the 3D printer, identifying a value of the adjusted parameter;

associating the value of the adjusted parameter with the difference;

storing the value of the adjusted parameter associated with the difference; and

responsive to identifying a subsequent difference between the element of the object and the analogous element of the benchmark image, using the associated value to adjust the parameter.

17. The method of claim 12, further comprising:

receiving, from the camera while the 3D printer is printing, another image of the object being printed by the 3D printer;

comparing the other image to the benchmark image;

identifying another difference between the element of the object and the analogous element of the benchmark image;

determining that the other difference exceeds a threshold;

responsive to determining that the other difference exceeds the threshold, sending a first control signal to the 3D printer, the first control signal effective to cause the 3D printer to pause printing the object; and

responsive to sending the first control signal, sending a second control signal, the second control signal effective to cause the 3D printer to display an error message.

18. The method of claim 17, wherein the second control signal is further effective to cause the 3D printer to transmit the error message to another device.

19. The method of claim 12, wherein the 3D printer includes a test target having one or more known visual characteristics, the method further comprising:

receiving, from the camera, an image of the test target;

analyzing the image to determine the visual characteristics of the test target as represented in the image;

comparing the visual characteristics of the test target as represented in the image to the known visual characteristics of the test target; and

adjusting operating parameters of the camera effective to match the visual characteristics of the test target, as represented in the image, to the known visual characteristics of the test target.

20. The method of claim 19, wherein the known visual characteristic of the test target is one or more of a shape, a color, a size, or a distance from the camera.