Control Systems for Three-Dimensional Printing

Abstract

Provided herein are systems, apparatuses and methods for monitoring a three-dimensional printing process. The three-dimensional printing process can be monitored in-situ and/or in real time. Monitoring of the three-dimensional printing process can be non-invasive. A computer control system can be coupled to one or more detectors and signal processing units to adjust the generation of a three-dimensional object that is formed by the three-dimensional printing.

1 . An apparatus for printing one or more three-dimensional objects comprising a controller that is programmed to: (a) direct a first energy source to generate a first energy beam that interacts with an optical window disposed in an enclosure in which the one or more three-dimensional objects are generated by three-dimensional printing, wherein the controller is operatively coupled to the first energy source; (b) direct at least one processing unit to process a signal indicative of an alteration in the first energy beam, wherein the alteration in the first energy beam is prognostic of a change in a cleanliness of the optical window, wherein the controller is operatively coupled to the at least one processing unit; and (c) evaluate a result to determine an adjustment to the three-dimensional printing considering the alteration in the first energy beam. 
     
     
         2 . The apparatus of  claim 1 , wherein the controller may further direct a mechanism used in the three-dimensional printing to alter at least one function based on the result, wherein the controller is operatively coupled to the mechanism. 
     
     
         3 . The apparatus of  claim 1 , wherein the alteration in the first energy beam comprises intensity or direction alteration. 
     
     
         4 . The apparatus of  claim 1 , wherein the signal is detected in real time during the printing of the one or more three-dimensional objects. 
     
     
         5 . The apparatus of  claim 4 , wherein the cleanliness of the optical window is monitored continuously during the three-dimensional printing of the one or more three-dimensional objects. 
     
     
         6 . The apparatus of  claim 4 , wherein the cleanliness of the optical window is monitored in discrete intervals. 
     
     
         7 . The apparatus of  claim 1 , wherein the signal comprises a reflection of the first energy beam from the optical window. 
     
     
         8 . The apparatus of  claim 7 , wherein the first energy beam is reflected from multiple locations of the optical window. 
     
     
         9 . The apparatus of  claim 1 , wherein the apparatus further comprises a second energy source that generates a second energy beam that transforms at least a portion of a material bed to form the one or more three-dimensional objects, which material bed is disposed in the enclosure, and which second energy source is disposed adjacent to the enclosure. 
     
     
         10 . The apparatus of  claim 9 , wherein the second energy beam is the same as the first energy beam. 
     
     
         11 . The apparatus of  claim 1 , wherein the signal comprises one or more signals, and wherein the controller generates a map of the optical window using the one or more signals. 
     
     
         12 . An apparatus for printing one or more three-dimensional objects comprising:
 an enclosure comprising an optical window, the enclosure configured to enclose the one or more three-dimensional object during a three-dimensional printing;   a first energy source that is configured to generate a first energy beam that interacts with the optical window; and   an energy beam detector configured to detect one or more signals comprising an alteration in the first energy beam that is indicative of a change in a cleanliness of the optical window, wherein the first energy source and the energy beam detector are disposed adjacent to the enclosure.   
     
     
         13 . The apparatus of  claim 12 , wherein alteration in the first energy beam comprises intensity or direction alteration of the first energy beam. 
     
     
         14 . The apparatus of  claim 12 , wherein the energy beam detector comprises an optical sensor. 
     
     
         15 . The apparatus of  claim 12 , wherein the energy beam detector comprises a temperature sensor. 
     
     
         16 . The apparatus of  claim 12 , wherein the energy beam detector comprises a spectrum analyzer. 
     
     
         17 . The apparatus of  claim 12 , wherein the apparatus further comprises a second energy source that is configured to generate a second energy beam that transforms at least a portion of a material bed to form the one or more three-dimensional objects, which material bed is disposed in the enclosure, and which second energy source is disposed adjacent to the enclosure. 
     
     
         18 . The apparatus of  claim 17 , wherein the change in the cleanliness of the optical window is used to adjust at least one characteristic of a second energy beam. 
     
     
         19 . The apparatus of  claim 18 , wherein the at least one characteristic comprises a power delivered by the second energy beam, a cross section of the second energy beam, a focus parameter of the second energy beam, a pulsing sequence of the second energy beam, or a rate of movement of the second energy beam. 
     
     
         20 . The apparatus of  claim 17 , wherein the second energy beam is the same as the first energy beam. 
     
     
         21 . The apparatus of  claim 12 , wherein the change in the cleanliness of the optical window is used to determine an initiation of a cleaning procedure of the optical window. 
     
     
         22 . The apparatus of  claim 21 , wherein the cleaning procedure comprises a physical or a chemical removal of debris. 
     
     
         23 . The apparatus of  claim 22 , wherein the cleaning procedure comprises ablation of the debris.