System and method for remote direct material deposition

• US 6,580,959 B1
• Filed: 05/19/2000
• Issued: 06/17/2003
• Est. Priority Date: 03/11/1999
• Status: Expired due to Term

• Current Assignee: DM3D Technology, LLC
• Original Assignee: Precision Optical Manufacturing
• Inventors: Mazumder, Jyoti
• Primary Examiner(s): Picard, Leo
• Assistant Examiner(s): Bahta, Kidest
• Application Number:
  US09/575,857
• Time in Patent Office: 1,124 Days
• Field of Search: 700/121, 700/166, 700/182, 700/112, 700/174, 700/169, 700/120, 700/119, 703/3, 706/46
• US Class Current: 700/121
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 10/80 Data acquisition or data processing
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: G05B 19/4185 characterised by the network communication
• CPC Class Codes: G05B 2219/31457 Factory remote control, monitoring through internet
• CPC Class Codes: G05B 2219/45238 Tape, fiber, glue, material dispensing in layers, beads, filling, sealing
• CPC Class Codes: G05B 2219/49019 Machine 3-D slices, to build 3-D model, stratified object manufacturing SOM
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

A system and method for remotely controlling the fabrication of a product at a local manufacturing site. The product is fabricated by depositing successive material layers through a local laser-aided, feedback-controlled, direct material deposition system. The system is equipped with strain gages, optical sensors and acoustic sensors generating signals which are processed in a local computer to determine the temperature, strain and residual stress of the product during fabrication. A feedback controller interfaces with the local computer and with a numerical controller and operates to control the material deposition process. The local numerical controller receives a file of a digitized description of the product from the remote computer, preferably via an Internet connection. The local computer sends temperature, strain and stress data to the remote computer, enabling a designer interfacing with the remote computer to monitor, control and modify the fabrication of the product in real time on line. The fabrication process is recorded by video or television camera and the shown in real-time on a screen display connected to the remote computer.

Claims

1. A remote control manufacturing system, comprising:

a remote computer system for generating and editing a design description of a product;

a local manufacturing system for fabricating the product in accordance with the design description using a laser-aided direct material deposition (DMD) process interfaced to a numerical controller, the DMD process being characterized in that the laser is used to create a melt pool into which powder or other feed material is delivered to create three-dimensional objects; and

a communications link facilitating the electronic transfer of design, manufacturing and control information between the remote computer system and the local manufacturing system, thereby enabling the remote computer to monitor, control and modify the fabrication process at the local manufacturing system.

2. The remote control manufacturing system of claim 1, wherein the manufacturing system interfaces with a feedback controller.

3. The remote control manufacturing system of claim 1, wherein the local manufacturing system includes one or more sensors to collect temperature, strain or stress data for transmission to the remote computer system.

4. The remote control manufacturing system of claim 1, wherein the manufacturing information includes visual images of the product being fabricated.

5. The remote control manufacturing system of claim 1, wherein the remote computer system includes software for generating a deposition tool path file from the description of the product.

6. The remote control manufacturing system of claim 5, wherein the remote computer system includes software for minimizing the size of the deposition tool path file.

7. The remote control manufacturing system of claim 1, wherein a user interfaces to the communications link through an Internet browser.

8. A remote control manufacturing system, comprising:

a laser-aided direct material deposition (DMD) system for fabricating a three-dimensional product by depositing successive material layers on a substrate, the material deposition system comprising;

a plurality of sensors providing outputs;

a local computer receiving and processing the sensor outputs to generate fabrication progress information; and

a feedback controller interfaced to the local computer and a numerical controller, the feedback controller being operative to control the material deposition process; and

a remote computer system, comprising;

a computerized description of the product;

a software package for creating a file of a deposition tool path for the fabrication of the product; and

a communications system for sending the tool path file to and receiving the fabrication progress information from the local computer, so that the fabrication of the product can be monitored, controlled and modified from the remote computer system through the local computer in real time on line.

9. The remote control manufacturing system of claim 8, wherein one of the sensors is an acoustic sensor.

10. The remote control manufacturing system of claim 8, wherein one of the sensors is an optical sensor.

11. The remote control manufacturing system of claim 8, wherein the fabrication progress information includes product temperature, stress or strain.

12. The remote control manufacturing system of claim 8, wherein the fabrication progress information includes the height of the deposition layers.

13. The remote control manufacturing system of claim 8, wherein the deposition tool path file is compressed to reduce its size at the remote computer system.

14. The remote control manufacturing system of claim 8, further comprising a video or television camera recording the fabrication process and transmitting the images to be viewed on a screen display situated at the remote computer system.

15. The remote control manufacturing system of claim 8, wherein the communications system connecting the local and remote computers includes an Internet browser.

16. A method associated with the remote-control fabrication of a product, comprising the steps of:

a) generating a file of a deposition tool path at a remote computer, and sending the file to a local computer at the manufacturing site;

b) transferring the deposition tool path file to a numerical controller interfaced to a laser-aided, direct material deposition system to fabricate the product on a substrate by depositing successive layers having a height;

c) collecting in the local computer real-time strain and temperature sensor data of the product during material deposition;

d) sending the strain and temperature data to the remote computer via a communications system; and

e) sending control commands from the remote computer to the local computer to control the material deposition process.

17. The method of claim 16, further comprising the steps of:

inputting the strain data into a finite-element program in the local computer to calculate residual stress data for the product; and

sending the stress data to the remote computer via the communications system.

18. The method of claim 16, wherein the file of the deposition tool path is compressed to reduce its size.

19. The method of claim 16, wherein the direct material deposition system of step b) includes a feedback controller for controlling the height of each deposited layer.

20. The method of claim 16, comprising the additional step of using a video or television camera to record the fabrication of the product and sending the images to a display connected to the remote computer.

21. The method of claim 16, comprising the additional step of:

editing the file of the deposition tool path in the remote computer and sending the edited file to the local computer.