Systems and methods for compensating for 3D shape deviations in additive manufacturing

1. A method performed by a computer system comprising processor electronics and at least one memory device, the method comprising:

obtaining a deformation model for an additive manufacturing (AM) machine, the deformation model representing deformation in a Spherical Coordinate System (SCS) including a first angular location variable and a second angular location variable, wherein the deformation model includes an in-plane deformation error model defined in a first Polar Coordinate System (PCS) using the first angular location variable from the SCS, and the deformation model includes an out-of-plane deformation error model defined in a second PCS using the second angular location variable from the SCS;

receiving a three dimensional (3D) model of an object to be built using the AM machine;

predicting deformation for the object using the deformation model applied to the 3D model, wherein the predicting comprises calculating for a given point on the 3D model separate in-plane and out-of-plane error components using the respective in-plane deformation error model and out-of-plane deformation error model;

selecting an amount of deformation compensation to effect by minimizing deviation for the predicted deformation; and

providing the selected amount of deformation compensation to modify the 3D model to compensate for deformation during creation by the AM machine;

wherein the deformation model for the AM machine is generated using a cookie-cutter model to trim a polygon from a cylinder, and the cookie-cutter model comprises a periodic waveform having an amplitude that alternates at a steady frequency between fixed minimum and maximum values.

2. The method of claim 1 , wherein obtaining the deformation model for an additive manufacturing machine comprises:

obtaining data associated with the AM machine during creation of one or more standard calibration parts.

3. The method of claim 1 wherein the deformation model for the AM machine is generated using a library of cookie-cutter models including a square wave model and a sawtooth wave model.

4. The method of claim 1 , wherein the minimizing deviation for the predicted deformation comprises minimizing an area deviation in the first PCS.

5. The method of claim 4 , wherein the minimizing an area deviation in the first PCS comprises calculating a minimized value corresponding to a total absolute area deviation.

6. The method of claim 1 , wherein the minimizing deviation for the predicted deformation comprises calculating an amount of compensation that is equivalent to an area deviation in the first PCS.

7. The method of claim 1 , wherein the minimizing deviation for the predicted deformation comprises minimizing volume deviation in the SCS.

8. The method of claim 7 , wherein providing the selected amount of deformation compensation to modify the 3D model comprises applying an in-plane deformation compensation to a 3D model layer-by-layer.

9. A system comprising:

an additive manufacturing (AM) machine; and

one or more computing devices coupled with the AM machine and programed to (i) obtain a deformation model for the AM machine, the deformation model representing deformation in a Spherical Coordinate System (SCS) including a first angular location variable and a second angular location variable, wherein the deformation model includes an in-plane deformation error model defined in a first Polar Coordinate System (PCS) using the first angular location variable from the SCS, and the deformation model includes an out-of-plane deformation error model defined in a second PCS using the second angular location variable from the SCS; (ii) receive a three dimensional (3D) model of an object to be built using the AM machine; (iii) predict deformation for the object using the deformation model applied to the 3D model, wherein the predicting comprises calculating for a given point on the 3D model separate in-plane and out-of-plane error components using the respective in-plane deformation error model and out-of-plane deformation error model; (iv) select an amount of deformation compensation to effect by minimizing volume deviation in the SCS for the predicted deformation; and (v) provide the selected amount of deformation compensation to modify the 3D model to compensate for deformation during creation by the AM machine; wherein the deformation model for the AM machine is generated using a cookie-cutter model to trim a polygon from a cylinder, and the cookie-cutter model comprises a periodic waveform having an amplitude that alternates at a steady frequency between fixed minimum and maximum values.

10. The system of claim 9 , wherein the one or more computing devices coupled with the AM machine are programed to obtain data associated with the AM machine during creation of one or more standard calibration parts.

11. The system of claim 9 , wherein the deformation model for the AM machine is generated using a library of cookie-cutter models including a square wave model and a sawtooth wave model.

12. The system of claim 9 , wherein the one or more computing devices coupled with the AM machine are programed to minimize an area deviation in the first PCS.

13. The system of claim 12 , wherein the one or more computing devices coupled with the AM machine are programed to minimize an area deviation in the first PCS by calculating a minimized value corresponding to a total absolute area deviation.

14. The system of claim 9 , wherein the one or more computing devices coupled with the AM machine are programed to calculate an amount of compensation that is equivalent to an area deviation in the first PCS.

15. The system of claim 9 , wherein the one or more computing devices coupled with the AM machine are programed to provide the selected amount of deformation compensation to modify the 3D model by applying an in-plane deformation compensation to a 3D model layer-by-layer.