Adaptive 3D printing
Methods provide for fabricating objects through additive manufacturing in a manner that compensates for deformations introduced during post-print processing, such as sintering. An initial model may be divided into a plurality of segments, the initial model defining geometry of an object. For each of the segments, modified geometry may be calculated, where the modified geometry compensates for a predicted deformation. Print parameters can then be updated to incorporate the modified geometry, where the print parameters define geometry of the printed object (e.g., configuration settings of the printer, a tool path, an object model). The object may then be printed based on the updated print parameters.
1. A method of printing an object, comprising:
dividing an object model into a plurality of slices with a thickness in a Z-direction, the model defining a first geometry of the object;
for each of the plurality of slices:
calculating, for each of the plurality of slices, a measure of stress using a cross-sectional area of the slice and calculated weight of material residing atop the slice according to
σ
=
g
·
m
above
segment
A
segment
;
and
predicting a deformation upon the slice will occur according to the measure of stress as a result of a sintering process following deposition of all the layers;
calculating a modified geometry for the slice, the modified geometry compensating for the deformation;
calculating a second geometry of the object from the collective of the modified geometries for each of the slices, the second geometry corresponding to a print geometry for the object; and
printing the object based on the second geometry.
2. The method of claim 1 , wherein the weight of material corresponds to weight of all material residing atop said slice.
3. The method of claim 1 , wherein the measured stress is associated with a corresponding compression force.
4. The method of claim 3 , wherein the corresponding compression force is associated with the deformation.
5. The method of claim 1 , wherein the measure of stress is calculated based on a location of a center of gravity of slices located above the slice.
6. The method of claim 1 , wherein before the printing step, the method further comprises generating a correction model of the object.
7. The method of claim 6 , wherein the correction model defines the modified print geometry of the object.
8. The method of claim 1 , wherein the printing comprises extruding feedstock.
9. The method of claim 8 , wherein the feedstock is extruded at a temperature between 160-250 degrees Celsius.
10. A method of printing an object, comprising:
dividing an object model into a plurality of slices with a thickness in a Z-direction, the object model defining a first geometry of the object;
calculating, for each slice from the plurality of slices:
a cross-sectional area in an X-Y plane;
a weight of material residing atop each slice;
a measure of stress using the calculated cross-sectional area and the calculated weight of material residing atop each slice according to
σ
=
g
·
m
above
segment
A
segment
;
and
a predicted compression force upon the slice resulting from the measure of stress;
determining, based on the predicted compression force, a deformation predicted to occur as a result of a sintering process following deposition of all of the layers;
calculating a modified geometry for each slice, wherein the modified geometry compensates for the predicted deformation;
calculating a second geometry of the object from the collective of the modified geometries for each of the slices, the second geometry corresponding to a print geometry for the object; and
printing the object based on the second geometry.
11. The method of claim 10 , wherein the weight of material corresponds to weight of all material residing atop said slice.
12. The method of claim 11 , wherein the corresponding compression force is associated with the deformation.
13. The method of claim 10 , wherein the measure of stress is calculated based on a location of a center of gravity of slices located above the slice.
14. The method of claim 10 , wherein the calculating for each slice further comprises quantifying a predicted loss of dimensional stability in debinding, due to loading.
15. The method of claim 10 , wherein before the printing step, the method further comprises generating a correction model of the object.
16. The method of claim 15 , wherein the correction model defines the modified print geometry of the object.
17. The method of claim 10 , wherein the printing comprises extruding feedstock.
18. The method of claim 17 , wherein the feedstock is extruded at a temperature between 160-250 degrees Celsius.