Adept three-dimensional printing
The present disclosure provides three-dimensional (3D) printing methods, apparatuses, systems, and non-transitory computer-readable medium. The disclosure delineates real time manipulation of three-dimensional printing to reduce deformation. The present disclosure further provides 3D object formed using the methods, apparatuses, and systems.
1. A method for forming a three-dimensional object, comprising:
(a) altering a three-dimensional model of a requested three-dimensional object to form an altered model, which altering comprises a structural alteration, wherein at least a first derivative of the difference between (i) the altered model and (ii) the three-dimensional model of the requested three-dimensional object, is continuous; and
(b) transforming at least a portion of a material bed with an energy beam according to the altered model, wherein the three-dimensional object is substantially similar to the requested three-dimensional object.
2. The method of claim 1 , wherein substantially similar is relative to the intended purpose of the three-dimensional object.
3. The method of claim 1 , wherein the at least the first derivative is a plurality of derivatives.
4. The method of claim 3 , wherein the plurality of derivatives comprises the first three derivatives.
5. The method of claim 1 , further comprising after (a) and before (b), generating a printing instruction using the altered model.
6. The method of claim 5 , wherein transforming in (b) is according to the printing instruction.
7. The method of claim 5 , wherein generating the printing instruction comprises using a simulation comprising thermal, mechanical, geometric, or material properties of the three-dimensional object or a portion thereof.
8. The method of claim 5 , wherein generating the printing instruction comprises using a geometric information deriving from a previously formed portion of the three-dimensional object.
9. The method of claim 8 , wherein the geometric information comprises a local thickness below a given layer, local build angle, proximity to an edge on a given layer, or proximity to layer boundary.
10. The method of claim 5 , wherein generating the printing instruction comprises dynamically adjusting the altered model in real time during the transforming in (b).
11. The method of claim 10 , wherein dynamically adjusting comprises using a closed loop control.
12. The method of claim 10 , wherein dynamically adjusting comprises using a real time measurement from one or more sensors.
13. The method of claim 5 , wherein generating the printing instruction comprises using geometric properties of the requested three-dimensional object.
14. The method of claim 7 , wherein the simulation is dynamically adjusted in real time during formation of the three-dimensional object.
15. The method of claim 10 , wherein the altered model is dynamically adjusted in real time during formation of at least one of: the three-dimensional object, a layer within the three-dimensional object, dwell time of the energy beam along a path of the energy beam during formation of the three-dimensional object, dwell time of the energy beam along a hatch line during formation of the three-dimensional object, and dwell time of the energy beam forming a melt pool during formation of the three-dimensional object.
16. The method of claim 12 , wherein the altered model is dynamically adjusted in real time during formation of at least one of: the three-dimensional object, a layer within the three-dimensional object, dwell time of the energy beam along a path of the energy beam during formation of the three-dimensional object, dwell time of the energy beam along a hatch line during formation of the three-dimensional object, and dwell time of the energy beam forming a melt pool during formation of the three-dimensional object.
17. The method of claim 14 , wherein the simulation is dynamically adjusted in real time during formation of at least one: 3D object, a layer within the 3D object, dwell time of the energy beam along a path of the energy beam during formation of the three-dimensional object, dwell time of the energy beam along a hatch line during formation of the three-dimensional object, and dwell time of the energy beam forming a melt pool during formation of the three-dimensional object.
18. The method of claim 10 , wherein dynamically adjusting the altered model comprises using a controller that includes a programmable circuit.
19. The method of claim 10 , wherein dynamically adjusting the altered model comprises sensing with a temperature sensor.
20. The method of claim 19 , wherein the temperature sensor comprises an optical sensor.
21. The method of claim 20 , wherein the optical sensor comprises a fiber optic sensor.
22. The method of claim 10 , wherein dynamically adjusting the altered model comprises sensing with a photo detector.
23. The method of claim 10 , wherein dynamically adjusting the altered model comprises sensing with fiber optic sensors.
24. The method of claim 1 , wherein the three-dimensional object comprises an average deviation value from a predetermined dimension of the requested three-dimensional object of at most about 100 micrometers.
25. The method of claim 3 , wherein the derivatives of the plurality of derivatives are continuous.
26. The method of claim 7 , wherein the simulation comprises a deviation in shape from a model of the requested three-dimensional object.
27. The method of claim 26 , wherein the deviation in shape is a corrective deviation that at least in part compensates for deformation during formation of the three-dimensional object.
28. The method of claim 27 , wherein the deformation is an accumulated deformation during formation of the three-dimensional object.
29. The method of claim 27 , wherein the deviation in shape excludes inserting kinks in the three-dimensional object.