System And Method For Controlling Three-Dimensional (3D) Printing Using Measured Processing Effects

Abstract

Complexity of a geometry of a desired (i.e., target) three-dimensional (3D) object being produced by an additive manufacturing system, as well as atypical behavior of the processes employed by such a system, pose challenges for producing a final version of the desired 3D object with fidelity relative to the desired object. An example embodiment enables such challenges to be overcome as a function of feedback to enable the final version to be produced with fidelity. The feedback may be at least one value that is associated with at least one characteristic of a printed object following processing of the printed object. Such feedback may be obtained as part of a calibration process of the 3 D printing system or as part of an operational process of the 3 D printing system.

What is claimed is: 
     
         1 . An additive manufacturing method, the method comprising:
 processing a three-dimensional (3D) object at a given processing stage that follows printing or follows a combination of printing and processing of the 3D object in a 3D printing system to transform the 3D object into a processed object, the processing including debinding or sintering of the 3D object;   identifying a discrepancy between a characteristic of the processed object and an expected characteristic, the discrepancy identified based on a value associated with the characteristic; and   adjusting a parameter based on the value, the parameter known to influence the characteristic and stored in a memory accessed by the 3D printing system, the parameter, in an adjusted state, being employed by the 3D printing system to affect its operating state that, in turn, produces a subsequent processed object with a corresponding characteristic closer to the expected characteristic relative to the characteristic of the processed object, the subsequent processed object having been processed by the given processing stage.   
     
     
         2 . The method of  claim 1 , further comprising printing the 3D object, iteratively, in successive layers and wherein the processing and adjusting are performed following iterations of the printing. 
     
     
         3 . The method of  claim 1 , further comprising de-binding or sintering the 3D object prior to the processing of the 3D object at the given processing stage. 
     
     
         4 . The method of  claim 1 , wherein the 3D object is a calibration object for calibrating the 3D printing system and further wherein the processing and adjusting are performed as part of the calibrating. 
     
     
         5 . The method of  claim 1 , further comprising obtaining the value by measuring the processed object. 
     
     
         6 . The method of  claim 5 , wherein the measuring is performed via a contact or non-contact measuring device, or a combination thereof 
     
     
         7 . The method of  claim 1 , wherein the value is a measurement of a geometric characteristic. 
     
     
         8 . The method of  claim 1 , wherein the characteristic is a dimension or geometric feature. 
     
     
         9 . The method of  claim 1 , wherein the characteristic is a location or geometric attribute associated with a mark or feature printed on the 3D object for determining a processing effect based on measurements of the mark or the feature and wherein the value enables the determining. 
     
     
         10 . The method of  claim 1 , wherein the subsequent processed object is of a higher geometric accuracy than the processed object relative to a target geometry, the higher geometric accuracy based on a comparison of differences between the target geometry and respective geometries of the processed object and the subsequent processed object. 
     
     
         11 . The method of  claim 1 , wherein the characteristic is mass and wherein the value is a mass value. 
     
     
         12 . The method of  claim 1 , wherein the subsequent processed object is of a higher mass accuracy than the processed object relative to a target mass, the higher mass accuracy based on a comparison of differences between the target mass and respective masses of the processed object and the subsequent processed object. 
     
     
         13 . The method of  claim 1 , wherein the characteristic is chemical composition and wherein the value is a concentration of a chemical constituent. 
     
     
         14 . The method of  claim 1 , wherein the subsequent processed object is of a higher chemical composition accuracy than the processed object relative to a target chemical composition, the higher chemical composition accuracy based on a comparison of differences between the target chemical composition and respective chemical compositions of the processed object and the subsequent processed object. 
     
     
         15 . The method of  claim 1 , further comprising triggering at least one action as a function of the value and wherein the at least one action triggered includes:
 generating an alert to schedule maintenance of the 3D printing system; or   signaling a malfunction of the 3D printing system.   
     
     
         16 . The method of  claim 15 , further comprising communicating the alert or malfunction via an operator interface or transmission of an electronic message to an electronic device communicatively coupled to the 3D printing system. 
     
     
         17 . The method of  claim 15 , wherein the alert generated or the malfunction signaled is based on the value and an expected value. 
     
     
         18 . The method of  claim 15 , wherein the value is a first value and wherein the method further comprises:
 obtaining a second value associated with the characteristic of the 3D object prior to the processing of the 3D object at the given post processing stage; and   wherein the alert generated or the malfunction signaled is based on the first value and the second value.   
     
     
         19 . The method of  claim 18 , wherein the alert generated or the malfunction signaled is based on the first value, the second value, and an expected value. 
     
     
         20 . The method of  claim 18 , further comprising obtaining the second value by measuring the 3D object prior to the processing of the 3D object at the given processing stage. 
     
     
         21 . The method of  claim 1 , wherein the value is a measured value. 
     
     
         22 . The method of  claim 1 , further comprising:
 identifying atypical deformation in the processed object based on the value; and   adjusting the parameter, automatically, based on the atypical deformation identified in order to obviate the atypical deformation in the subsequent processed object.   
     
     
         23 . The method of  claim 1 , wherein the parameter includes at least one scaling factor associated with an x, y, or z axis direction, the at least one scaling factor employed by the 3D printing system to offset shrinkage of the 3D object due to the given processing stage and wherein the adjusting includes adjusting the at least one scaling factor to offset shrinkage of the subsequent processed object in the x, y, or z axis direction. 
     
     
         24 . The method of  claim 1 , wherein the value is a first value and wherein the method further comprises:
 obtaining a second value associated with the characteristic of the 3D object prior to processing the 3D object at the given processing stage; and   wherein the adjusting includes adjusting as a function of the first value and the second value.   
     
     
         25 . The method of  claim 24 , wherein the adjusting is further a function of an expected value. 
     
     
         26 . The method of  claim 24 , wherein obtaining the second value includes measuring the 3D object prior to the processing of the 3D object at the given processing stage. 
     
     
         27 . The method of  claim 26 , wherein the measuring is performed via contact or non-contact measuring device, or a combination thereof 
     
     
         28 . The method of  claim 24 , wherein obtaining the second value includes obtaining the second value from (i) a 3D object model employed by the printing stage, (ii) the 3D object prior to processing of the 3D object at the given processing stage, (iii), the processed object or (iv) a combination thereof. 
     
     
         29 . The method of  claim 24 , wherein the adjusting includes:
 determining a difference between the first value and the second value; and   adjusting the parameter based on the difference determined.   
     
     
         30 . The method of  claim 29 , wherein the adjusting further includes:
 comparing the difference determined to an expected value; and   adjusting the parameter based on the comparison.   
     
     
         31 . The method of  claim 29 , wherein determining the difference includes computing a ratio of the first value and the second value or computing the difference via subtraction. 
     
     
         32 . The method of  claim 1 , wherein:
 the parameter includes at least one 3D fabrication parameter employed by the printing; and   wherein the adjusting includes adjusting the at least one 3D fabrication parameter to cause dilation, contraction, warping, or a combination thereof, of the corresponding characteristic of the subsequent processed object relative to the characteristic of the processed object.   
     
     
         33 . The method of  claim 1 , wherein:
 the parameter is an extrusion profile parameter employed by the printing; and   wherein the adjusting adjusts the extrusion profile parameter.   
     
     
         34 . The method of  claim 1 , wherein the parameter includes at least one debinding process parameter or debinding process cycle parameter that is applied by the controller to control a debinding process employed by the given processing stage and wherein the controller is further configured to adjust the at least one debinding process or debinding process cycle parameter to compensate for a specification of the debinding process determined to be out of range via the value obtained. 
     
     
         35 . The method of  claim 1 , wherein the parameter includes at least one furnace parameter or furnace cycling parameter that is applied to control a furnace employed by the given processing stage. 
     
     
         36 . The method of  claim 35 , wherein adjusting the at least one furnace or furnace cycling parameter compensates for a specification of the furnace determined to be out of range via the value. 
     
     
         37 . An additive manufacturing system, the system comprising:
 a printing stage configured to print a three-dimensional (3D) object;   a plurality of processing stages, a given processing stage of the plurality of processing stages configured to transform the 3D object into a processed object, the given processing stage being a debinding or a sintering stage that follows the printing stage or follows the printing stage and one or more of the plurality of processing stages; and   a controller configured to identify a discrepancy between a characteristic of the processed object and an expected characteristic, the discrepancy identified based on a value associated with the characteristic, and adjust a parameter based on the value, the parameter known to influence the characteristic and stored in a memory accessed by the system, the parameter, in an adjusted state, being employed by the system to affect its operating state that, in turn, produces a subsequent processed object with a corresponding characteristic closer to the expected characteristic relative to the characteristic of the processed object, the subsequent processed object having been processed by the given processing stage.   
     
     
         38 . The system of  claim 37 , further comprising an obtaining device configured to obtain the value associated with the characteristic of the processed object and wherein the controller is operatively coupled to the printing stage, the given processing stage, the plurality of processing stages, the obtaining device, or a combination thereof. 
     
     
         39 . The system of  claim 37 , further comprising an obtaining device configured to obtain the value associated with the characteristic of the processed object and wherein the printing stage, the given processing stage, the plurality of processing stages, or a combination thereof, includes the obtaining device. 
     
     
         40 . The system of  claim 37 , further comprising an obtaining device configured to obtain the value associated with the characteristic of the processed object. 
     
     
         41 . The system of  claim 37 , wherein the 3D object is a calibration object for calibrating the system. 
     
     
         42 . The system of  claim 37 , further comprising an obtaining device configured to obtain the value associated with the characteristic of the processed object and wherein, to obtain the value, the obtaining device is configured to measure the processed object. 
     
     
         43 . The system of  claim 42 , wherein the obtaining device includes a contact or non-contact measuring device, or a combination thereof, to measure the processed object. 
     
     
         44 . The system of  claim 37 , wherein the value is a measurement of a geometric characteristic. 
     
     
         45 . The system of  claim 37 , wherein the characteristic is a dimension or geometric feature. 
     
     
         46 . The system of  claim 37 , wherein the characteristic is a location or geometric attribute associated with a mark or feature printed on the 3D object for determining a processing effect based on measurements of the mark or the feature. 
     
     
         47 . The system of  claim 37 , wherein the subsequent processed object is of a higher geometric accuracy than the processed object relative to a target geometry, the higher geometric accuracy based on a comparison of differences between the target geometry and respective geometries of the processed object and the subsequent processed object. 
     
     
         48 . The system of  claim 37 , wherein the characteristic is mass and wherein the value is a mass value. 
     
     
         49 . The system of  claim 37 , wherein the subsequent processed object is of a higher mass accuracy than the processed object relative to a target mass, the higher mass accuracy based on a comparison of differences between the target mass and respective masses of the processed object and the subsequent processed object. 
     
     
         50 . The system of  claim 37 , wherein the characteristic is chemical composition and wherein the value is a chemical composition value. 
     
     
         51 . The system of  claim 37 , wherein the subsequent processed object is of a higher chemical composition accuracy than the processed object relative to a target chemical composition, the higher chemical composition accuracy based on a comparison of differences between the target chemical composition and respective chemical compositions of the processed object and the subsequent processed object. 
     
     
         52 . The system of  claim 37 , wherein the controller is further configured to trigger at least one action as a function of the value and wherein, to trigger the at least one action, the controller is further configured to:
 generate an alert to schedule maintenance of the system; or   signal a malfunction of the system.   
     
     
         53 . The system of  claim 52 , wherein the controller is further configured to communicate the alert or malfunction via an operator interface or transmission of an electronic message to an electronic device communicatively coupled to the system. 
     
     
         54 . The system of  claim 52 , wherein the alert generated or the malfunction signaled is based on the value and an expected value. 
     
     
         55 . The system of  claim 52 , further comprising an obtaining device configured to obtain the value associated with the characteristic of the processed object, wherein the value is a first value, and:
 wherein the obtaining device is further configured to obtain a second value associated with the characteristic of the 3D object prior to processing the 3D object at the given processing stage; and   wherein the controller is further configured to generate the alert or signal the malfunction based on the first value and the second value.   
     
     
         56 . The system of  claim 55 , wherein the alert generated or the malfunction signaled is based on the first value, the second value, and an expected value. 
     
     
         57 . The system of  claim 55 , wherein, to obtain the second value, the obtaining device is further configured to measure the 3D object prior to processing of the 3D object at the given processing stage. 
     
     
         58 . The system of  claim 37 , wherein the value is a measured value. 
     
     
         59 . The system of  claim 37 , wherein the controller is further configured to:
 identify atypical deformation in the processed object based on the value; and   adjust the parameter, automatically, based on the atypical deformation identified in order to obviate the atypical deformation in the subsequent processed object.   
     
     
         60 . The system of  claim 37 , wherein the parameter includes at least one scaling factor associated with an x, y, or z axis direction, and wherein the at least one scaling factor is employed by the system to offset shrinkage of the 3D object due to the given processing stage and wherein the controller is further configured to adjust the at least one scaling factor to offset shrinkage of the subsequent processed object in the x, y, or z axis direction. 
     
     
         61 . The system of  claim 37 , further comprising an obtaining device configured to obtain the value associated with the characteristic of the processed object, wherein the value is a first value and:
 wherein the obtaining device is further configured to obtain a second value associated with the characteristic of the 3D object prior to processing of the 3D object at the given processing stage; and   the controller is further configured to adjust the parameter as a function of the first value and the second value.   
     
     
         62 . The system of  claim 61 , wherein the controller is further configured to adjust the parameter as a function of an expected value. 
     
     
         63 . The system of  claim 61 , wherein the obtaining device is further configured to obtain the second value by measuring the 3D object prior to processing of the 3D object at the given processing stage. 
     
     
         64 . The system of  claim 63 , wherein the obtaining device is a contact or non-contact measuring device, or a combination thereof. 
     
     
         65 . The system of  claim 61 , wherein the obtaining device is further configured to obtain the second value from (i) a 3D object model employed by the printing stage, (ii) the 3D object prior to processing of the 3D object at the given processing stage, (iii) the processed object, or (iv) a combination thereof. 
     
     
         66 . The system of  claim 61 , wherein the controller is further configured to:
 determine a difference between the first value and the second value; and   adjust the parameter based on the difference determined.   
     
     
         67 . The system of  claim 66 , wherein the controller is further configured to:
 compare the difference determined to an expected value; and   adjust the parameter based on the comparison.   
     
     
         68 . The system of  claim 66 , wherein to determine the difference, the controller is further configured to compute a ratio of the first value and second value or perform subtraction. 
     
     
         69 . The system of  claim 37 , wherein:
 the parameter includes at least one 3D fabrication parameter employed by the printing stage; and   wherein the controller is further configured to adjust the at least one 3D fabrication parameter to cause dilation, contraction, warping, or a combination thereof, in a corresponding characteristic of the subsequent processed object relative to the characteristic of the processed object.   
     
     
         70 . The system of  claim 37 , wherein:
 the parameter is an extrusion profile parameter employed by the printing stage; and   wherein the controller is further configured to adjust the extrusion profile parameter.   
     
     
         71 . The system of  claim 37 , wherein the parameter includes at least one debinding process parameter or debinding process cycle parameter that is applied by the controller to control a debinding process employed by the given processing stage and wherein the controller is further configured to adjust the at least one debinding process or debinding process cycle parameter to compensate for a specification of the debinding process determined to be out of range via the value obtained. 
     
     
         72 . The system of  claim 37 , wherein the parameter includes at least one furnace parameter or furnace cycle parameter that is applied by the controller to control a furnace employed by the given processing stage. 
     
     
         73 . The system of  claim 72 , wherein the controller is further configured to adjust the at least one furnace or furnace cycling parameter to compensate for a specification of the furnace determined to be out of range via the value obtained.