Method and device for manufacturing objects having improved surface characteristic

• US 10,671,664 B2
• Filed: 06/12/2017
• Issued: 06/02/2020
• Est. Priority Date: 06/14/2016
• Status: Active Grant

• Current Assignee: EOS GmbH Electro Optical Systems
• Original Assignee: EOS GmbH Electro Optical Systems
• Inventors: Sippel, Dominik
• Primary Examiner(s): Karim, Ziaul
• Application Number:
  US15/619,730
• Publication Number:
  US 20170357671A1
• Time in Patent Office: 1,086 Days
• Field of Search: None
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/80 Data acquisition or data processing
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: G05B 19/4097 characterised by using design data to control NC machines, e.g. CAD/CAM G05B19/4093 takes precedence
• CPC Class Codes: G06F 16/5862 using texture
• CPC Class Codes: G06F 17/10 Complex mathematical operations function generation by table look-up G06F1/03; evaluation of elementary functions by calculation G06F7/544
• CPC Class Codes: G06F 2119/18 Manufacturability analysis or optimisation for manufacturability
• CPC Class Codes: Y02P 10/25 Process efficiency
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A computer-based method of providing control commands of a control command set for manufacturing a three-dimensional object with an additive manufacturing device. The method includes at least the following steps: a step of allocating input data that represent at least a partial surface of the object to be manufactured, where the partial surface has an initial surface texture defined by a set of initial texture parameter values that characterize the geometry of the initial surface texture; a step of determining a set of target texture parameter values that differ from the set of initial texture parameter values, and a step of generating control commands of a control command set to manufacture the partial surface by the additive manufacturing device with a surface texture that is defined by the set of target texture parameter values.

Claims

1. A computer-based method of providing control commands of a control command set for manufacturing a three-dimensional object by an additive manufacturing device, the method comprising at least the following steps:

allocating input data representing at least a partial surface of an entire surface of the three-dimensional object to be manufactured, wherein the partial surface has an initial surface texture defined by a set of initial texture parameter values that characterize a geometry of the initial surface texture, wherein the input data includes a set of preferential texture parameter values that characterize a preferential surface texture of the partial surface;

comparing the set of preferential texture parameter values with different sets of existing texture parameter values and determining a set of existing texture parameter values by the step of comparing the set of preferential texture parameter values with the different sets of existing texture parameter values which is a set of target texture parameter values having values that are the least different to the set of preferential texture parameter values;

assigning an existing control command set of an additive manufacturing device to each of the sets of existing texture parameter values to manufacture the partial surface by the additive manufacturing device with a surface texture that is defined by the corresponding set of existing texture parameter values; and

generating control commands of a control command set to manufacture the partial surface by the additive manufacturing device with a surface texture that is defined by the set of target texture parameter values, wherein either the existing control command set is determined as the control command set for manufacturing the three-dimensional object that is assigned to the set of existing texture parameter values identified in the comparison step, or, if the existing control command set includes only the control commands that geometrically describe the surface texture characterized by the identified set of existing texture parameter values, integrating the control commands into a complete control command set.

2. A computer-based method according to claim 1, further comprising determining a set of interaction parameter values having a number of components, wherein a value for an interaction parameter is assigned to each component and an interaction parameter characterizes an interaction of the at least one partial surface of the object to be manufactured with a surrounding of the at least one partial surface of the object to be manufactured.

3. A computer-based method according to claim 1, further comprising assigning interaction parameter values to the components of the set of interaction parameter values via a user input.

4. A computer-based method according to claim 1, further comprising optimizing the set of interaction parameter values based on a user input and/or an automatic optimization algorithm before the comparison with the sets of existing interaction parameter values.

5. A computer-based method according to claim 1, wherein after the set of existing interaction parameter values having values that are the least different to the set of interaction parameter values has been identified, the identified set of existing interaction parameter values is subjected to an optimization procedure based on a user input and/or an automatic optimization algorithm and the comparison set is again executed with the resulting set of interaction parameter values.

6. A computer-based method according to claim 1, wherein the set of interaction parameter values and the sets of existing interaction parameter values each have more than one component and the difference of a set of existing interaction parameter values to the set of interaction parameter values is determined based on a metric defined by weighting the components that involve a user input.

7. A computer-based method according to claim 1, wherein the components of the interaction parameter sets contain values for at least one of the following interaction parameters:

an interaction parameter that characterizes an interaction of the surface texture with a fluid flowing in contact with the surface texture, the interaction parameter being the frictional resistance and/or an ability to repel water and/or noise;

an interaction parameter that characterizes a haptics of the surface; and

an interaction parameter that characterizes a reflection characteristic of the surface.

9. A method of manufacturing a three-dimensional object by an additive manufacturing device, comprising at least the following steps:

providing control commands of a control command set by a method according to claim 1; and

manufacturing the three-dimensional object by the additive manufacturing device based on the provided control commands.

11. A computer program comprising a command sequence for carrying out a method according to claim 1.

8. A preprocessor device for carrying out a method of providing control commands for an additive manufacturing device, the preprocessor device comprising:

an allocation processor component that allocates input data representing at least a partial surface of an entire surface of the three-dimensional object to be manufactured, wherein the partial surface has an initial surface texture that is defined by a set of initial texture parameter values that characterize a geometry of the initial surface texture, wherein the input data includes a set of preferential texture parameter values that characterize a preferential surface texture of the partial surface;

a comparing processor component that compares the set of preferential texture parameter values with different sets of existing texture parameter values and determines a set of existing texture parameter values by the step of comparing the set of preferential texture parameter values with the different sets of existing texture parameter values which is a set of target texture parameter values having values that are the least different to the set of preferential texture parameter values;

an assignment processor component that assigns an existing control command set of an additive manufacturing device to each of the sets of existing texture parameter values to manufacture the partial surface by the additive manufacturing device with a surface texture that is defined by the corresponding set of existing texture parameter values; and

a control command set generation processor component that, when in operation, generates control commands of a control command set to manufacture the partial surface by the additive manufacturing device with a surface texture defined by the set of target texture parameter values, wherein either the existing control command set is determined as the control command set for manufacturing the three-dimensional object that is assigned to the set of existing texture parameter values identified in the comparison step, or, if the existing control command set includes only the control commands that geometrically describe the surface texture characterized by the identified set of existing texture parameter values, integrating the control commands into a complete control command set.

10. An apparatus for carrying out an additive manufacturing method, comprising a preprocessor device according to claim 8 or wherein the apparatus is connected to the preprocessor device according to claim 8 such that the apparatus may communicate via a signal with the preprocessor device.

12. A computer program including a command sequence carried out in a device according to claim 8.

13. A computer program including a command sequence carried out in a device according to claim 10.

14. A computer-based method of providing control commands of a control command set for manufacturing a three-dimensional object by an additive manufacturing device, wherein the method comprises at least the following steps:

allocating input data representing at least a partial surface of an entire surface of the three-dimensional object to be manufactured, wherein the partial surface has an initial surface texture defined by a set of initial texture parameter values that characterize a geometry of the initial surface texture determining a set of interaction parameter values having a number of components, wherein a value for an interaction parameter is assigned to each component and an interaction parameter characterizes an interaction of the at least one partial surface of the object to be manufactured with a surrounding of the at least one partial surface of the object to be manufactured;

comparing the set of interaction parameter values with different sets of existing interaction parameter values and of determining a set of existing interaction parameter values by the step of comparing the set of preferential texture parameter values with the different sets of existing texture parameter values that are the least different to the set of interaction parameter values;

assigning a set of texture parameter values to each set of existing interaction parameter values;

assigning an existing control command set of an additive manufacturing device to each of the sets of existing interaction parameter values to manufacture the partial surface by the additive manufacturing device with a surface texture that is defined by the set of texture parameter values assigned to the set of existing interaction parameter values; and

generating control commands for a control command set, in that the existing control command set that is assigned to the set of existing interaction parameter values identified in the comparison step, either is set as control command set for manufacturing the object or, when the existing control command set includes only those control commands that geometrically describe the surface texture characterized by the set of texture parameter values which is assigned to the set of existing interaction parameter values identified in the comparison step, integrating the control commands into a complete control command set.

15. The computer-based method according to claim 14, wherein the input data includes a set of preferential texture parameter values that characterize a preferential surface texture of the partial surface.