Temperature determination in additive manufacturing systems

• US 10,639,848 B2
• Filed: 09/28/2015
• Issued: 05/05/2020
• Est. Priority Date: 09/28/2015
• Status: Active Grant

• Current Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Original Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Inventors: Vilajosana, Xavier, Cortes, Sebastia, Rossow, Yngvar
• Primary Examiner(s): Ali, Mohammad
• Assistant Examiner(s): Sanders, Joshua T
• Application Number:
  US15/568,405
• Publication Number:
  US 20180186079A1
• Time in Patent Office: 1,681 Days
• Field of Search: 700119
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes

Abstract

A method of controlling a heating sub-system in an additive manufacturing system. The method comprising receiving thermal imaging information from a temperature sensing subsystem, receiving additive manufacturing media concentration information from an additive manufacturing media concentration information database, on the basis of the received thermal imaging information and additive manufacturing media concentration information, for each pixel area in the plurality of pixel areas, determining the temperature for each additive manufacturing media agent in the plurality of additive manufacturing media agents which is present in the respective pixel area, and on the basis of the determined temperatures for each pixel area and additive manufacturing media agent, controlling the power to a heating subsystem employed in the given additive manufacturing process.

Claims

1. An additive manufacturing system, the system comprising a controller configured to:

operate a fluid dispenser to selectively dispense at least one of a plurality of print agents to a print-bed area containing a layer of a part being printed in a given three-dimensional printing process;

obtain temperature information from one or more temperature sensors, wherein each of the one or more temperature sensors is configured to measure a temperature of a respective pixel area in a plurality of pixel areas in the print-bed area for at least one layer of the part being printed;

obtain agent concentration information, the received agent concentration information comprising, for each pixel area in the plurality of pixel areas, a concentration of each of the plurality of printing agents present in the respective pixel area;

on the basis of the obtained temperature information and agent concentration information, for each pixel area in the plurality of pixel areas, determine the temperature for each printing agent in the plurality of printing agents which is present in the respective pixel area, the different printing agents having different respective temperatures within that pixel area; and

on the basis of the determined temperatures for each pixel area and printing agent, determine a power to be applied to a heating subsystem employed in the given three-dimensional printing process.

2. The system of claim 1, the controller being configured to:

obtain further temperature information from the one or more temperature sensors, the obtained further temperature information comprising measured temperatures of pixel areas in the plurality of pixel areas for a subsequent stage of the given three-dimensional printing process;

on the basis of the obtained further temperature information and agent concentration information, for each pixel area in the plurality of pixel areas, further determine the temperature for each printing agent in the plurality of printing agents which is present in the respective pixel area; and

on the basis of the further determined temperatures for each pixel area and printing agent, dynamically update the power control to the heating subsystem employed in the subsequent stage of the given three-dimensional printing process.

3. The system of claim 1, the controller being configured to:

perform a lookup in a plurality of predetermined temperature adjustment data lookup tables, each lookup table in the plurality of predetermined temperature adjustment data lookup tables comprising predetermined temperature adjustment data for a set of different measured temperatures and different printing agent concentrations for a given printing agent in the plurality of printing agents,

wherein the power to be applied to the heating subsystem employed in the given three-dimensional printing process is further determined on the basis of the results of the performed lookup.

4. The system of claim 1, wherein controlling the power to the heating subsystem comprises determining a power to apply to each of a plurality of fusing lamps.

5. The system of claim 1, wherein the plurality of printing agents comprises two or more of:

powder agent,

a liquid fusing agent, and

a liquid detailing agent.

6. The system of claim 1, wherein the obtained temperature information comprises thermal imaging information from a plurality of thermal cameras.

7. The system of claim 1, wherein the controller is configured to transmit a control signal representative of the determined power to the heating subsystem employed in the given three-dimensional printing process.

8. The system of claim 1, further comprising:

a substrate supply mechanism to spread a layer of powder; and

a liquid ejection device to selective eject at least one of the plurality of printing agents into each layer of powder.

9. The system of claim 1, the controller to determine the power to be applied by the heating subsystem to each pixel area based on a current objective at that pixel area and temperature of a corresponding material in that pixel area.

10. The system of claim 9, wherein the current objective for a first pixel area is to melt material covered by an absorber agent, the controller to determine the power to be applied based on temperature of the absorber agent.

11. The system of claim 9, wherein the current objective for a first pixel area is to keep powder at a target temperature, the controller to determine the power to be applied based on determined temperature of the powder, the temperature of the powder determined based on both measured temperature of that pixel area and printing agent concentration information for that pixel area.

12. A method of controlling a heating sub-system in an additive manufacturing system, the method comprising:

operating a fluid dispenser to selectively dispense at least one of a plurality of additive manufacturing media agents to a bed area containing a layer of a part being printed in a given additive manufacturing process;

receiving thermal imaging information from a temperature sensing subsystem, the temperature sensing subsystem comprising one or more thermal cameras configured to measure the temperature of a respective pixel area in a plurality of pixel areas in the bed area;

receiving additive manufacturing media agent concentration information from an additive manufacturing media agent concentration information database, the received additive manufacturing media agent concentration information comprising, for each pixel area in the plurality of pixel areas, a concentration of each of the plurality of additive manufacturing media agents present in the respective pixel area;

on the basis of the received thermal imaging information and additive manufacturing media agent concentration information, for each pixel area in the plurality of pixel areas, determining a different respective temperature for each additive manufacturing media agent in the plurality of additive manufacturing media agents which is present in the respective pixel area; and

on the basis of the determined temperatures for each pixel area and additive manufacturing media agent, controlling the power to a heating subsystem employed in the given additive manufacturing process.

13. The method of claim 12, comprising:

receiving further thermal imaging information from the temperature sensing subsystem, the temperature sensing subsystem comprising one or more thermal cameras configured to measure the temperature of a respective pixel area in a plurality of pixel areas in the bed area for a subsequent stage of the given additive manufacturing process;

on the basis of the received further thermal imaging information and additive manufacturing media agent concentration information, for each pixel area in the plurality of pixel areas, further determining the temperature for each additive manufacturing media agent in the plurality of additive manufacturing media agents which is present in the respective pixel area; and

on the basis of the further determined temperatures for each pixel area and additive manufacturing media agent, dynamically updating the power control to the heating subsystem employed in the subsequent stage of the given additive manufacturing process.

14. The method of claim 12, comprising obtaining, from one or more predetermined temperature adjustment data lookup tables, predetermined temperature adjustment data for a plurality of different measured temperatures and different additive manufacturing media agent concentrations for each of the additive manufacturing media agents in the plurality of additive manufacturing media agents,

wherein the power to the heating subsystem employed in the given additive manufacturing process is further controlled on the basis of the obtained predetermined temperature adjustment data.

15. The method of claim 14, wherein the one or more predetermined temperature adjustment data lookup tables are stored as media settings in the additive manufacturing system.

16. The method of claim 12, wherein controlling the power to the heating subsystem comprises controlling a power to apply to each of a plurality of fusing lamps.

17. The method of claim 12, wherein controlling the power to the heating subsystem comprises transmitting one or more control signals to the heating subsystem.

18. The method of claim 12, wherein the plurality of additive manufacturing media comprises

liquid fusing media, and

liquid detailing media.

19. The method of claim 12, further comprising determining the power of the heating subsystem for each pixel area based on a current objective at that pixel area and temperature of a corresponding material in that pixel area,

wherein, when the current objective for that pixel area is to melt material covered by an absorber agent, the method determining the power of the heating subsystem for that pixel area based on temperature of the absorber agent;

and

wherein, when the current objective for that pixel area is to keep powder at a target temperature, the method determining the power of the heating subsystem for that pixel area based on determined temperature of the powder, the temperature of the powder determined based on both measured temperature of that pixel area and printing agent concentration information for that pixel area.

20. A non-transitory computer-readable storage medium storing instructions that, if executed by a processor of a three-dimensional printing system, cause the processor to:

operate a fluid dispenser to selectively dispense at least one of a plurality of print agents to a print-bed area containing a layer of a part being formed in a given three-dimensional printing process;

receive thermal imaging information from a temperature sensing subsystem, the temperature sensing subsystem comprising a plurality of thermal cameras configured to measure a temperature of a respective pixel area in a plurality of pixel areas in the print-bed area;

receive agent concentration information, the received agent concentration information comprising, for each pixel area in the plurality of pixel areas, a concentration of each of a plurality of printing agents present in the respective pixel area;

access a printing agent concentration information database, the printing agent concentration information database comprising a plurality of temperature correction lookup tables, each lookup table in the plurality of temperature correction lookup tables comprising temperature correction data for a plurality of different measured temperatures and different printing agent concentrations, wherein the accessing results in, for each pixel area in the plurality of pixel areas, corrected temperatures for each printing agent in the plurality of printing agents which is present in the respective pixel area; and

on the basis of the corrected temperatures for each pixel area and printing agent, control the power to a plurality of fusing lamps employed in the three-dimensional printing process.