Verification and adjustment systems and methods for additive manufacturing

Abstract

Verification and adjustment systems and methods correct at least one build error that is detected in a component built by additive manufacturing (hereinafter “AM”). The systems and methods comprise an AM device, a first imaging device, a second imaging device and computer-implement steps for correcting the build error present in the component. The first imaging device collects first digital images or data of the component and is positioned at a first orientation with respect to a build platform of the AM device. The second imaging device collects second digital images or data of the component and is positioned at a second orientation with respect to the build platform.

1 . A verification and adjustment method for correcting at least one build error present in a component built by additive manufacturing, the method comprising:
 extracting digital 3D geometric data of the component from collected digital data, wherein the collected digital data is based on the component built on a build platform of an additive manufacturing device, wherein the collected digital data comprises digital 2D images collected from a first imaging device associated with the additive manufacturing device and digital 3D images collected from a second imaging device associated with the additive manufacturing device;   detecting at least one build error present in the component built on the build platform by comparing the extracted digital 3D geometric data with a first digital 3D model of the component, wherein a first digital 3D printable file of the component comprises the first digital 3D model of the component;   generating a second digital 3D model of the component based on the detected at least one build error present in the component, wherein the second digital 3D model accounts for, or corrects, the detected at least one build error present in the component; and   providing a second digital 3D printable file that accounts for, or corrects, the detected at least one build error by changing the line-by-line code of the first digital 3D printable file to incorporate the generated second digital 3D model of the component.   
     
     
         2 . The method according to  claim 1 , further comprising:
 building one or more corrected components based on the second digital 3D printable file.   
     
     
         3 . The method according to  claim 1 , wherein the first imaging device is located above the build platform and the second imaging device is located at a side of the additive manufacturing device. 
     
     
         4 . The method according to  claim 3 , wherein the second imaging device is stationary, or movable, with respect to the build platform of the additive manufacturing device, and is parallel, or nonparallel, with respect to the build platform of the additive manufacturing device. 
     
     
         5 . The method according to  claim 1 , wherein the collected digital 2D data comprises digital 2D images of a plurality of build layers of the component built on the build platform and the collected digital 3D data comprises digital 3D images of the plurality of build layers of the component built on the build platform. 
     
     
         6 . The method according to  claim 5 , wherein the plurality of build layers comprises each build layer added by the additive manufacturing device to build the component on the build platform. 
     
     
         7 . The method according to  claim 1 , wherein the first imaging device and the second imaging devices are both directed at a build layer immediately added to the component by the additive manufacturing device. 
     
     
         8 . The method according to  claim 1 , wherein at least one imaging device, selected from the first imaging device and the second imaging device, is mounted on at least one print head of the additive manufacturing device. 
     
     
         9 . The method according to  claim 1 , further comprising:
 changing firmware associated with the additive manufacturing device based on the extracted digital 3D geometric data.   
     
     
         10 . The method according to  claim 1 , further comprising:
 introducing corrections into subsequent building of the component, when the component is only a partially built component, wherein the corrections are based on, or determined from, the extracted digital 3D geometric data.   
     
     
         11 . The method according to  claim 1 , further comprising:
 acquiring the collected digital data from (i) at least two different angle with respect to the build platform and (ii) inside or outside an interior space of the additive manufacturing device, wherein the interior space is configured to house the component and the build platform during the additive manufacturing.