Dynamic layer selection in additive manufacturing using sensor feedback
First Claim
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1. An additive manufacturing method, comprising:
- receiving process code at an additive manufacturing apparatus defining a plurality of design layers of a part model, wherein;
a thickness of each respective design layer of the plurality of design layers is less than an expected thickness of a deposited material layer from the additive manufacturing apparatus, andthe plurality of design layers comprise all design layers of the part model;
obtaining, from a sensor, a calibration measurement, the calibration measurement indicating a distance from the sensor to a build surface of the additive manufacturing apparatus;
selecting a current design layer from a plurality of design layers of the part model;
depositing, from a deposition element of the additive manufacturing apparatus, a first material layer of a part corresponding to the current design layer of the part model, wherein the first material layer is thicker than the thickness of the current design layer;
obtaining, from the sensor, a plurality of material layer measurements, each of the material layer measurements indicating a distance from the sensor to the first material layer;
determining, based on the plurality of material layer measurements and the calibration measurement, a height metric, wherein the height metric is a median height of the first material layer relative to the build surface;
selecting a new design layer from the plurality of design layers of the part model based on the height metric;
determining a maximum width of the new design layer; and
depositing, from the deposition element of the additive manufacturing apparatus, a second material layer of the part corresponding to the selected new design layer of the part model and having a width at least equal to the determined maximum width of the new design layer.
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Abstract
The present disclosure relates to methods and systems for improving layer selection in additive manufacturing. In particular, the present disclosure relates to methods and systems for improving layer selection in additive manufacturing using sensor feedback. In some examples, the sensor may be a distance sensor, and design layers may be selected dynamically based on determined part layer heights after layer deposition.
21 Citations
17 Claims
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1. An additive manufacturing method, comprising:
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receiving process code at an additive manufacturing apparatus defining a plurality of design layers of a part model, wherein; a thickness of each respective design layer of the plurality of design layers is less than an expected thickness of a deposited material layer from the additive manufacturing apparatus, and the plurality of design layers comprise all design layers of the part model; obtaining, from a sensor, a calibration measurement, the calibration measurement indicating a distance from the sensor to a build surface of the additive manufacturing apparatus; selecting a current design layer from a plurality of design layers of the part model; depositing, from a deposition element of the additive manufacturing apparatus, a first material layer of a part corresponding to the current design layer of the part model, wherein the first material layer is thicker than the thickness of the current design layer; obtaining, from the sensor, a plurality of material layer measurements, each of the material layer measurements indicating a distance from the sensor to the first material layer; determining, based on the plurality of material layer measurements and the calibration measurement, a height metric, wherein the height metric is a median height of the first material layer relative to the build surface; selecting a new design layer from the plurality of design layers of the part model based on the height metric; determining a maximum width of the new design layer; and depositing, from the deposition element of the additive manufacturing apparatus, a second material layer of the part corresponding to the selected new design layer of the part model and having a width at least equal to the determined maximum width of the new design layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. An additive manufacturing apparatus, comprising:
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a user interface; a deposition element; a directed energy source; a material feed; a process motion system; a build surface motion system comprising a build surface; a distance sensor; a tool configured to remove material from a part being manufactured; a memory comprising a plurality of design layers representing a part to be additively manufactured; and a control system, wherein the control system is configured to execute program code and cause the additive manufacturing apparatus to; receive process code at an additive manufacturing apparatus defining a plurality of design layers of a part model, wherein; a thickness of each respective design layer of the plurality of design layers is less than an expected thickness of a deposited material layer from the additive manufacturing apparatus, and the plurality of design layers comprise all design layers of the part model; obtain, from the distance sensor, a calibration measurement, the calibration measurement indicating a distance from the distance sensor to the build surface of the additive manufacturing apparatus; select a current design layer from the plurality of design layers of a part model; deposit, from the deposition element, a first material layer of a part corresponding to the current design layer of the part model, wherein the first material layer is thicker than the thickness of the current design layer; obtain, from the distance sensor, a plurality of material layer measurements, each of the material layer measurements indicating a distance from the distance sensor to the material layer; determine, based on the plurality of material layer measurements and the calibration measurement, a height metric, wherein the height metric is a median height of the first material layer relative to the build surface; and select a new design layer from the plurality of design layers of the part model based on the height metric; determine a maximum width of the new design layer; and deposit, from the deposition element of the additive manufacturing apparatus, a second material layer of the part corresponding to the selected new design layer of the part model and having a width at least equal to the determined maximum width of the new design layer. - View Dependent Claims (12, 13, 14, 15, 16, 17)
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Specification