Three-dimensional objects and their formation

Abstract

The present disclosure provides three-dimensional (3D) methods, apparatuses, software (e.g., non-transitory computer readable medium), and systems for the formation of at least one desired 3D object; comprising use of a geometric model, a physics based model, one or more markers, one or more modes, or any combination thereof. The disclosure provides reduction of deformation that may be caused by the forming process of the 3D object.

1 .- 30 . (canceled) 
     
     
         31 . A method for forming a three-dimensional object, comprising: (a) forming a test object using a geometric model of the three-dimensional object, and one or more model markers disposed on and/or in the geometric model of the three-dimensional object, the test object having one or more physical markers that correspond to the one or more model markers; and (b) comparing locations of the one or more model markers with locations of the one or more physical markers. 
     
     
         32 . The method of  claim 31 , further comprising (c) generating a corrected geometric model using the comparing in (b). 
     
     
         33 . The method of  claim 32 , further comprising (d) forming the three-dimensional object using the corrected geometric model. 
     
     
         34 . The method of  claim 32 , further comprising repeating (a), (b) and (c) using iteratively adjusted geometric models and a plurality of test objects until the locations of the one or more model markers converge with the locations of the one or more physical markers. 
     
     
         35 . The method of  claim 31 , further comprising generating a physics model that employs an estimated change of at least one characteristic of the three-dimensional object present upon formation of the three-dimensional object. 
     
     
         36 . The method of  claim 35 , further comprising forming a simulated object employing the physics model. 
     
     
         37 . The method of  claim 36 , further comprising comparing the simulated object with the test object. 
     
     
         38 . The method of  claim 36 , wherein the physics model employs an estimated thermo-mechanical change in the three-dimensional object present upon formation of the three-dimensional object. 
     
     
         39 . The method of  claim 31 , further comprising adding and/or removing the one or more model markers to the geometric model. 
     
     
         40 . The method of  claim 31 , wherein the one or more model markers comprise a protrusion, a depression, or a deletion. 
     
     
         41 . The method of  claim 31 , wherein the one or more model markers comprise tessellation borders, or point clouds. 
     
     
         42 . The method of  claim 31 , wherein the one or more model markers are positioned on a surface and/or in the geometric model. 
     
     
         43 . The method of  claim 31 , wherein forming comprises printing using three-dimensional printing. 
     
     
         44 . The method of  claim 31 , wherein the one or more physical markers comprise a pore, dislocation, crack, microstructure, crystal structure, or a metallurgical morphology. 
     
     
         45 . A system for forming a three-dimensional object, the system comprising one or more controllers that are collectively or separately configured to direct: (a) forming a test object using a geometric model of the three-dimensional object, and one or more model markers disposed on and/or in the geometric model of the three-dimensional object, the test object having one or more physical markers that correspond to the one or more model markers; and (b) comparing locations of the one or more model markers with locations of the one or more physical markers. 
     
     
         46 . The system of  claim 45 , wherein forming comprises printing using three-dimensional printing. 
     
     
         47 . The system of  claim 45 , wherein the system further comprises at least one sensor configured to sense the one or more physical markers, wherein the one or more controllers is configured to (i) control sensing and/or (ii) use sensing data, of the one or more physical markers. 
     
     
         48 . The system of  claim 47 , wherein the one or more controllers is configured to (i) control sensing and/or (ii) use sensing data, of the one or more physical markers after forming of: the three-dimensional object and/or test object. 
     
     
         49 . The system of  claim 45 , wherein the system further comprises at least one detector that is operationally coupled to the one or more controllers, the at least one detector configured to detect as least one characteristic of the forming. 
     
     
         50 . The system of  claim 49 , wherein the one or more controllers is configured to control the at least one detector and/or control one or more process parameters present upon a detection by the at least one detector. 
     
     
         51 . The system of  claim 49 , wherein the at least one detector is configured to detect a temperature during the forming, wherein the one or more controllers is configured to control detection of the temperature. 
     
     
         52 . The system of  claim 49 , wherein the at least one detector is configured to detect one or more of cleanliness, pressure, humidity, and oxygen level of an atmosphere surrounding the three-dimensional object during the forming. 
     
     
         53 . The system of  claim 45 , wherein the one or more controllers is configured to direct (c) generating a corrected geometric model using the comparing in (b). 
     
     
         54 . The system of  claim 53 , wherein the one or more controllers is configured to direct (d) forming the three-dimensional object using the corrected geometric model. 
     
     
         55 . The system of  claim 53 , wherein the one or more controllers is configured to direct repeating (a), (b) and (c) using iteratively adjusted geometric models and a plurality of test objects, until locations of the one or more model markers converge with locations of the one or more physical markers. 
     
     
         56 . The system of  claim 45 , wherein the one or more controllers is configured to direct generating a physics model that employs an estimated change of at least one characteristic of the three-dimensional object present upon formation of the three-dimensional object. 
     
     
         57 . The system of  claim 56 , further comprising forming a simulated object employing the physics model. 
     
     
         58 . The system of  claim 45 , wherein the one or more model markers comprises a protrusion, a depression, or a deletion. 
     
     
         59 . The system of  claim 45 , wherein the one or more model markers comprise tessellation borders, or point clouds. 
     
     
         60 . The system of  claim 45 , wherein the one or more physical markers comprise a pore, dislocation, crack, microstructure, crystal structure, or a metallurgical morphology.