IP Library › Granted Patent US 12694163

Granted Patent B2

US 12694163 · App. 17/418,792 · Granted Jul 28, 2026

Dimensions in additive manufacturing

Inventors: Victor Diego Gutierrez (Sant Cugat del Valles, ES); Manuel Freire Garcia (Sant Cugat del Valles, ES); Enrique Gurdiel Gonzalez (Sant Cugat del Valles, ES)

Assignee: Peridot Print LLC

G06F30/10 B29C64/386 B33Y50/00 G05B19/40931 G05B2219/35148 G06F2111/10 G06F2119/18

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Quick Facts

Patent No.: US 12694163
App. No.: 17/418,792
Granted: Jul 28, 2026
Kind: B2

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Abstract

An example method includes obtaining, by at least one processor, a plurality of categorised indications of deviations from expected dimensions for at least one object generated using an additive manufacturing apparatus wherein the categories comprise at least two of a first dimension type comprising dimensions which are expected to increase on application of a positive offset to object model data used to generate an object, a second dimension type comprising dimensions which are expected to decrease on application of a positive offset to the object to object model data used to generate an object, and a third dimension type comprising dimensions which are expected to be unaffected by application of an offset to object model data used to generate an object. The method may include determining a geometrical compensation model to apply to object model data for generating objects using additive manufacturing to compensate for anticipated deviations in dimensions.

Claims (94)

1 . A method comprising:

receiving, by a processor, object model data for an object,

wherein the object is to be additively manufactured by an additive-manufacturing apparatus depositing layers of build material, selectively applying fusing agent to the layers on a layer-by-layer basis in accordance with the object model data, and selectively fusing the build material via energy application,

wherein the fusing agent promotes fusing of the build material during the energy application by absorbing the energy,

wherein the object model data specifies a nominal value of each first dimension of a plurality of first dimensions of the object, each first dimension being defined between a first external surface point of the object and a first non-surface point of the object,

and wherein either or both of:

when the fusing agent is applied to the build material in regions that are to be fused, but the build material in neighboring regions that are not to be fused become sufficiently heated during the energy application to also fuse, each first dimension of one or more of the first dimensions is greater than the nominal value, as first dimensional deformation when the object is additively manufactured, and

after the fusing agent is selectively applied to the build material and the build material is selectively fused via the energy application, and some of the build material shrinks during subsequent cooling, each first dimension of one or more other of the first dimensions is smaller than the nominal value, as second dimensional deformation when the object is additively manufactured;

generating, by the additive manufacturing apparatus, the object using the object model data, such that either or both of the first and second dimensional deformations occur;

determining, by the processor, a deviation between the nominal value and an actual value of each first dimension of the object as generated from the object model data, wherein the actual value for each of at least one of the first dimensions is greater or smaller than the nominal value per the first or second dimensional deformation, respectively;

based on the determined deviation for each first dimension, determining, by the processor, a scaling factor and a positive offset factor that minimizes a sum of first squared quantities corresponding to the first dimensions,

wherein each first squared quantity comprises a product of the actual value of a corresponding first dimension and the scaling factor, plus half of the offset factor, minus the nominal value of the corresponding first dimension;

modifying, by the processor, the object model data, using the scaling factor and the positive offset factor to compensate for either or both of the first and second dimensional deformation when the additive manufacturing apparatus generates the object again; and

generating, by the additive manufacturing apparatus, the object using the modified object model data, such that modification of the object model data and usage of the modified object model data to generate the object again at least ameliorates either or both of the first and second dimensional deformations, improving dimensional accuracy of the generated object.

2 . The method of claim 1 , wherein the object model data further specifies a nominal value of each second dimension of one or more second dimensions of the object, each second dimension defined between a second internal surface point of the object and a second non-surface point of the object,

wherein the method further comprises determining, by the processor, a deviation between the nominal value and an actual value of each second dimension of the object as generated from the object model data using the additive manufacturing apparatus,

wherein the scaling factor and the positive offset factor are determined based further on the determined deviation for each second dimension to minimize the sum of the first squared quantities, plus a sum of one or more second square quantities corresponding to the one or more second dimensions, and

wherein each second squared quantity comprises a product of the actual value of a corresponding second dimension and the scaling factor, minus half of the offset factor, minus the nominal value of the corresponding second dimension.

3 . The method of claim 1 , wherein the object model data further specifies a nominal value of each third dimension of one or more third dimensions of the object, each third dimension defined between a pair of third non-surface points of the object,

wherein the method further comprises determining, by the processor, a deviation between the nominal value and an actual value of each third dimension of the object as generated from the object model data using the additive manufacturing apparatus,

wherein the scaling factor and the positive offset factor are determined based further on the determined deviation for each third dimension to minimize the sum of the first squared quantities, plus a sum of one or more third square quantities corresponding to the one or more third dimensions, and

wherein each third squared quantity comprises a product of the actual value of a corresponding third dimension and the scaling factor, minus the nominal value of the corresponding third dimension.

4 . The method of claim 3 , wherein the object model data further specifies a nominal value of each second dimension of one or more second dimensions of the object, each second dimension defined between a second internal surface point of the object and a second non-surface point of the object,

5 . The method of claim 1 , wherein the object model data further specifies a nominal value of each fourth dimension of one or more fourth dimensions of the object, each fourth dimension defined between a pair of fourth external surface points of the object,

wherein the method further comprises determining, by the processor, a deviation between the nominal value and an actual value of each fourth dimension of the object as generated from the object model data using the additive manufacturing apparatus,

wherein the scaling factor and the positive offset factor are determined based further on the determined deviation for each fourth dimension to minimize the sum of the first squared quantities, plus a sum of one or more fourth square quantities corresponding to the one or more fourth dimensions, and

wherein each fourth squared quantity comprises a product of the actual value of a corresponding fourth dimension and the scaling factor, plus the offset, minus the nominal value of the corresponding fourth dimension.

6 . The method of claim 1 , wherein the object model data further specifies a nominal value of each fifth dimension of one or more fifth dimensions of the object, each fifth dimension defined between a pair of fifth internal surface points of the object,

wherein the method further comprises determining, by the processor, a deviation between the nominal value and an actual value of each fifth dimension of the object as generated from the object model data using the additive manufacturing apparatus,

wherein the scaling factor and the positive offset factor are determined based further on the determined deviation for each fifth dimension to minimize the sum of the first squared quantities, plus a sum of one or more fifth square quantities corresponding to the one or more fifth dimensions, and

wherein each fifth squared quantity comprises a product of the actual value of a corresponding fifth dimension and the scaling factor, minus the offset, minus the nominal value of the corresponding fifth dimension.

7 . The method of claim 6 , wherein the object model data further specifies a nominal value of each fourth dimension of one or more fourth dimensions of the object, each fourth dimension defined between a pair of fourth external surface points of the object,

wherein the scaling factor and the positive offset factor are determined based further on the determined deviation for each fourth dimension to minimize the sum of the first squared quantities, plus a sum of the one or more fifth squared quantities, plus a sum of one or more fourth square quantities corresponding to the one or more fourth dimensions, and

8 . A system comprising:

a processor; and

a memory storing instructions executable by the processor to:

receive object model data for an object specifying a nominal value of each second dimension of one or more second dimensions of the object, each second dimension defined between a second internal surface point of the object and a second non-surface point of the object;

determine a deviation between the nominal value and an actual value of each second dimension of the object as generated from the object model data using an additive manufacturing apparatus;

based on the determined deviation for each first dimension, determine a scaling factor and a positive offset factor that minimizes a sum of one or more second squared quantities corresponding to the one or more second dimensions,

modify the object model data, using the scaling factor and the positive offset factor; and

cause the additive manufacturing apparatus to generate the object using the modified object model data to compensate for expected dimensional deformation to improve dimensional accuracy of the generated object.

9 . The system of claim 8 , wherein the object model data further specifies a nominal value of each first dimension of one or more first dimensions of the object, each first dimension defined between a first external surface point of the object and a first non-surface point of the object,

wherein the instructions are executable by the processor to further determine a deviation between the nominal value and an actual value of each first dimension of the object as generated from the object model data using the additive manufacturing apparatus,

wherein the scaling factor and the positive offset factor are determined based further on the determined deviation for each first dimension to minimize the sum of the one or more second squared quantities, plus a sum of one or more first square quantities corresponding to the one or more first dimensions, and

10 . The system of claim 8 , wherein the object model data further specifies a nominal value of each third dimension of one or more third dimensions of the object, each third dimension defined between a pair of third non-surface points of the object,

wherein the instructions are executable by the processor to further determine a deviation between the nominal value and an actual value of each third dimension of the object as generated from the object model data using the additive manufacturing apparatus,

wherein the scaling factor and the positive offset factor are determined based further on the determined deviation for each third dimension to minimize the sum of the one or more second squared quantities, plus a sum of one or more third square quantities corresponding to the one or more third dimensions, and

wherein each third squared quantity comprises a product of the actual value of a corresponding third dimension and the scaling factor, minus the nominal value of the corresponding third dimension.

11 . The system of claim 10 , wherein the object model data further specifies a nominal value of each first dimension of one or more first dimensions of the object, each first dimension defined between a first external surface point of the object and a first non-surface point of the object,

wherein the scaling factor and the positive offset factor are determined based further on the determined deviation for each first dimension to minimize the sum of the one or more second squared quantities, plus the sum of the one or more third square quantities, plus a sum of one or more first square quantities corresponding to the one or more first dimensions, and

12 . The system of claim 8 , wherein the object model data further specifies a nominal value of each fourth dimension of one or more fourth dimensions of the object, each fourth dimension defined between a pair of fourth external surface points of the object,

wherein the instructions are executable by the processor to further determine a deviation between the nominal value and an actual value of each fourth dimension of the object as generated from the object model data using the additive manufacturing apparatus,

wherein the scaling factor and the positive offset factor are determined based further on the determined deviation for each fourth dimension to minimize the sum of the one or more second squared quantities, plus a sum of one or more fourth square quantities corresponding to the one or more fourth dimensions, and

13 . The system of claim 8 , wherein the object model data further specifies a nominal value of each fifth dimension of one or more fifth dimensions of the object, each fifth dimension defined between a pair of fifth internal surface points of the object,

wherein the instructions are executable by the processor to further determine a deviation between the nominal value and an actual value of each fifth dimension of the object as generated from the object model data using the additive manufacturing apparatus,

wherein the scaling factor and the positive offset factor are determined based further on the determined deviation for each fifth dimension to minimize the sum of the one or more second squared quantities, plus a sum of one or more fifth square quantities corresponding to the one or more fifth dimensions, and

14 . The system of claim 13 , wherein the object model data further specifies a nominal value of each fourth dimension of one or more fourth dimensions of the object, each fourth dimension defined between a pair of fourth external surface points of the object,

wherein the scaling factor and the positive offset factor are determined based further on the determined deviation for each fourth dimension to minimize the sum of the one or more second squared quantities, plus a sum of the one or more fifth squared quantities, plus a sum of one or more fourth square quantities corresponding to the one or more fourth dimensions, and

15 . The system of claim 8 , further comprising the additive manufacturing apparatus.

16 . A non-transitory machine-readable medium storing instructions executable by a processor to perform processing comprising:

receiving object model data for an object specifying a nominal value of each first dimension of one or more third dimensions of the object, each third dimension defined between a pair of third non-surface points of the object;

determining a deviation between the nominal value and an actual value of each third dimension of the object as generated from the object model data using an additive manufacturing apparatus;

based on the determined deviation for each third dimension, determining, by the processor, a scaling factor that minimizes a sum of one or more third squared quantities corresponding to the one or more third dimensions,

wherein each third squared quantity comprises a product of the actual value of a corresponding third dimension and the scaling factor, minus the nominal value of the corresponding third dimension;

modifying the object model data, using the scaling factor; and

sending the modified object model data to the additive manufacturing apparatus to generate the object from the modified object model data,

wherein modification of the object model data improves dimensional accuracy of the object that is generated by the additive manufacturing apparatus by compensating for expected dimensional deformation during generation of the object by the additive manufacturing apparatus.

17 . The non-transitory machine-readable medium of claim 16 , wherein the object model data further specifies a nominal value of each first dimension of one or more first dimensions of the object, each first dimension defined between a first external surface point of the object and a first non-surface point of the object,

wherein the processing further comprises determining a deviation between the nominal value and an actual value of each first dimension of the object as generated from the object model data using the additive manufacturing apparatus,

wherein the scaling factor and a positive offset factor are determined based on the determined deviation for each third dimension and the determined deviation for each first dimension to minimize the sum of the one or more third squared quantities, plus a sum of one or more first square quantities corresponding to the one or more first dimensions,

wherein the object model data is modified based on both the scaling factor and the positive offset factor, and

18 . The non-transitory machine-readable medium of claim 16 , wherein the object model data further specifies a nominal value of each second dimension of one or more second dimensions of the object, each second dimension defined between a second internal surface point of the object and a second non-surface point of the object,

wherein the processing further comprises determining a deviation between the nominal value and an actual value of each second dimension of the object as generated from the object model data using the additive manufacturing apparatus,

wherein the scaling factor and a positive offset factor are determined based on the determined deviation for each third dimension and the determined determination for each second dimension to minimize the sum of the one or more third squared quantities, plus a sum of one or more second square quantities corresponding to the one or more second dimensions,

wherein the object model data is modified based on both the scaling factor and the positive offset factor, and

19 . The non-transitory machine-readable medium of claim 16 , wherein the object model data further specifies a nominal value of each fourth dimension of one or more fourth dimensions of the object, each fourth dimension defined between a pair of fourth external surface points of the object, wherein the processing further comprises determining a deviation between the nominal value and an actual value of each fourth dimension of the object as generated from the object model data using the additive manufacturing apparatus,

wherein the scaling factor and a positive offset factor are determined based on the determined deviation for each third dimension and the determined determination for each fourth dimension to minimize the sum of the one or more third squared quantities, plus a sum of one or more fourth square quantities corresponding to the one or more fourth dimensions,

wherein the object model data is modified based on both the scaling factor and the positive offset factor, and