System and Method for Providing Variation in Bead Size to Improve Geometrical Accuracy of Deposited Layers in An Additive Manufacturing Process

Content Provider	The Lens
Abstract	A system and method is provided for providing variation in bead size to improve geometrical accuracy of deposited layers in an additive manufacturing process. The system may include at least one processor configured to receive a plurality of toolpaths along which a 3D printer deposits beads of material in a plurality of layers in order to additively build up a product. Based on the toolpaths, the processor may determine an image for each layer and may process the images based on a default bead size to determine a bead size image for each layer comprised of pixels having values that specify bead size for locations along the toolpaths. The image processing produces pixel values for the bead size images that vary in magnitude at a plurality of different locations along the toolpaths in order to represent smaller and larger bead sizes relative to the default bead size, which smaller and larger bead sizes respectively minimize over-depositing and under-depositing of material by the 3D printer that would otherwise occur with the default bead size at these different locations along the toolpaths.
Related Links	https://www.lens.org/lens/patent/011-726-655-570-63X/frontpage
Language	English
Publisher Date	2019-11-21
Access Restriction	Open
Content Type	Text
Resource Type	Patent
Jurisdiction	United States of America
Date Applied	2017-09-26
Applicant	Siemens Product Lifecycle Man Software Inc
Application No.	201716475904
Claim	A system for providing variation in bead size to improve geometrical accuracy of deposited layers in an additive manufacturing process comprising: at least one processor configured via executable instructions included in at least one memory to: receive a plurality of toolpaths according to which a 3D printer is operable to deposit beads of material in a plurality of layers in order to additively build up a product; determine an image for each layer based on the toolpaths; process the images based on a default bead size to determine a bead size image for each layer comprised of pixels having values that specify bead size for locations along the toolpaths, wherein the image processing produces pixel values for the bead size images that vary in magnitude at a plurality of different locations along the toolpaths in order to represent smaller and larger bead sizes relative to the default bead size, which smaller and larger bead sizes respectively minimize over-depositing and under-depositing of material by the 3D printer that would otherwise occur with the default bead size at these different locations along the toolpaths; generate instructions for driving the 3D printer to additively build up the product, based on the toolpaths and the pixel values along the toolpaths, which generated instructions vary process parameters in order to vary the size of the beads according to the pixel values. The system according to claim 1 , wherein the image for each layer includes a binary toolpath image, wherein pixels of each binary toolpath image have one value that specifies a toolpath location and a second value that specifies the absence of a toolpath location, wherein the image processing is carried out using the binary toolpath images and data corresponding to the default bead size. The system according to claim 2 , wherein the image processing includes processing each binary toolpath image into a grayscale image that depicts locations at which bead size should be increased to fill holes not filled by toolpaths with the default bead size, wherein the bead size images are generated based on the grayscale images. The system according to claim 3 , wherein the image processing includes: processing each binary toolpath image to produce a boundary image depicting an outer boundary of each layer; processing each binary toolpath image to produce a distance transform image having pixels with values that represent distance to the nearest nozzle head location; processing each distance transform image to produce a local maxima contour image that depicts boundaries where extruded material from the nozzle is expected to flow and fill a region of a layer; unifying the boundary images and the local maxima contour images to form a contour image; and blurring the contour image to form the grayscale image. The system according to claim 4 , wherein blurring the contour image is based on a Gaussian kernel with standard deviation corresponding to half the default bead size in pixel coordinates, wherein the image processing further includes: inverting and normalizing the grayscale image; setting pixel values for pixels that do not correspond to the toolpaths to zero; and producing the bead size images by rescaling non-zero values of the pixel values to correspond to bead size radii in pixel coordinates at the locations of the toolpaths. The system according to claim 1 , wherein the process parameters are selected to control bead size along the toolpaths based on the pixel values of the bead size images, such that for a given point along the toolpaths, the nearest nonzero pixel is used to control bead size at that point, wherein the process parameters include laser power, nozzle speed, or any combination thereof. The system according to claim 1 , wherein the generated instructions include G-code, further comprising the 3D printer with a nozzle that outputs material and a laser that melts the material, where the default bead size corresponds to a width of a laser beam produced by the laser, wherein the at least one processor is configured to generate the toolpath instructions from a solid model retrieved from a data store. A method for providing variation in bead size to improve geometrical accuracy of deposited layers in an additive manufacturing process comprising: through operation of at least one processor: receiving a plurality of toolpaths according to which a 3D printer is operable to deposit beads of material in a plurality of layers in order to additively build up a product; determining an image for each layer based on the toolpaths; processing the images based on a default bead size to determine a bead size image for each layer comprised of pixels having values that specify bead size for locations along the toolpaths, wherein the image processing produces pixel values for the bead size images that vary in magnitude at a plurality of different locations along the toolpaths in order to represent smaller and larger bead sizes relative to the default bead size, which smaller and larger bead sizes respectively minimize over-depositing and under-depositing of material by the 3D printer that would otherwise occur with the default bead size at these different locations along the toolpaths; generating instructions for driving the 3D printer to additively build up the product, based on the toolpaths and the pixel values along the toolpaths, which generated instructions vary process parameters in order to vary the size of the beads according to the pixel values. The method according to claim 8 , wherein the image for each layer includes a binary toolpath image, wherein pixels of each binary toolpath image have one value that specifies a toolpath location and a second value that specifies the absence of a toolpath location, wherein the image processing is carried out using the binary toolpath images and data corresponding to the default bead size. The method according to claim 9 , wherein the image processing includes processing each binary toolpath image into a grayscale image that depicts locations at which bead size should be increased to fill holes not filled by toolpaths with the default bead size, wherein the bead size images are generated based on the grayscale images. The method according to claim 10 , wherein the image processing includes: processing each binary toolpath image to produce a boundary image depicting an outer boundary of each layer; processing each binary toolpath image to produce a distance transform image having pixels with values that represent distance to the nearest nozzle head location; processing each distance transform image to produce a local maxima contour image that depicts boundaries where extruded material from the nozzle is expected to flow and fill a region of a layer; unifying the boundary images and the local maxima contour images to form a contour image; and blurring the contour image to form the grayscale image. The method according to claim 11 , wherein blurring the contour image is based on a Gaussian kernel with standard deviation corresponding to half the default bead size in pixel coordinates, wherein the image processing further includes: inverting and normalizing the grayscale image; setting pixel values for pixels that do not correspond to the toolpaths to zero; and producing the bead size images by rescaling non-zero values of the pixel values to correspond to bead size radii in pixel coordinates at the locations of the toolpaths. The method according to claim 8 , wherein the process parameters are selected to control bead size along the toolpaths based on the pixel values of the bead size images, such that for a given point along the toolpaths, the nearest nonzero pixel is used to control bead size at that point, wherein the process parameters include laser power, nozzle speed, or any combination thereof. The method according to claim 8 , wherein the generated instructions include G-code, further comprising the 3D printer with a nozzle that outputs material and a laser that melts the material, where the default bead size corresponds to a width of a laser beam produced by the laser, wherein the at least one processor is configured to generate the toolpaths from a solid model retrieved from a data store, further comprising: building the product with the 3D printer configured based on the generated instructions. A non-transitory computer readable medium encoded with processor executable instructions that when executed by at least one processor, cause the at least one processor to receive a plurality of toolpaths according to which a 3D printer is operable to deposit beads of material in a plurality of layers in order to additively build up a product; determine an image for each layer based on the toolpaths; process the images based on a default bead size to determine a bead size image for each layer comprised of pixels having values that specify bead size for locations along the toolpaths, wherein the image processing produces pixel values for the bead size images that vary in magnitude at a plurality of different locations along the toolpaths in order to represent smaller and larger bead sizes relative to the default bead size, which smaller and larger bead sizes respectively minimize over-depositing and under-depositing of material by the 3D printer that would otherwise occur with the default bead size at these different locations along the toolpaths; generate instructions for driving the 3D printer to additively build up the product, based on the toolpaths and the pixel values along the toolpaths, which generated instructions vary process parameters in order to vary the size of the beads according to the pixel values. The system according to claim 15 , wherein the image for each layer includes a binary toolpath image, wherein pixels of each binary toolpath image have one value that specifies a toolpath location and a second value that specifies the absence of a toolpath location, wherein the image processing is carried out using the binary toolpath images and data corresponding to the default bead size. The system according to claim 16 , wherein the image processing includes processing each binary toolpath image into a grayscale image that depicts locations at which bead size should be increased to fill holes not filled by toolpaths with the default bead size, wherein the bead size images are generated based on the grayscale images. The system according to claim 17 , wherein the image processing includes: processing each binary toolpath image to produce a boundary image depicting an outer boundary of each layer; processing each binary toolpath image to produce a distance transform image having pixels with values that represent distance to the nearest nozzle head location; processing each distance transform image to produce a local maxima contour image that depicts boundaries where extruded material from the nozzle is expected to flow and fill a region of a layer; unifying the boundary images and the local maxima contour images to form a contour image; and blurring the contour image to form the grayscale image. The system according to claim 18 , wherein blurring the contour image is based on a Gaussian kernel with standard deviation corresponding to half the default bead size in pixel coordinates, wherein the image processing further includes: inverting and normalizing the grayscale image; setting pixel values for pixels that do not correspond to the toolpaths to zero; and producing the bead size images by rescaling non-zero values of the pixel values to correspond to bead size radii in pixel coordinates at the locations of the toolpaths. The system according to claim 15 , wherein the process parameters are selected to control bead size along the toolpaths based on the pixel values of the bead size images, such that for a given point along the toolpaths, the nearest nonzero pixel is used to control bead size at that point, wherein the process parameters include laser power, nozzle speed, or any combination thereof.
CPC Classification	ADDITIVE MANUFACTURING; i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION; ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING; e.g. BY 3-D PRINTING; STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING WORKING METALLIC POWDER;MANUFACTURE OF ARTICLES FROM METALLIC POWDER;MAKING METALLIC POWDER ;APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER SHAPING OR JOINING OF PLASTICS;SHAPING OF MATERIAL IN A PLASTIC STATE; NOT OTHERWISE PROVIDED FOR;AFTER-TREATMENT OF THE SHAPED PRODUCTS; e.g. REPAIRING CONTROL OR REGULATING SYSTEMS IN GENERAL;FUNCTIONAL ELEMENTS OF SUCH SYSTEMS;MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS ELECTRIC DIGITAL DATA PROCESSING Climate Change Mitigation Technologies In The Production Or Processing Of Goods
Extended Family	013-283-943-867-502 166-857-702-689-176 186-885-408-345-173 019-584-499-790-656 186-005-872-186-665 085-488-610-361-184 011-726-655-570-63X
Patent ID	20190351620
Inventor/Author	Jaiswal Prakhar Musuvathy Suraj Ravi Arisoy Erhan Madeley David
IPC	B29C64/393 B29C64/20 B33Y30/00 B33Y50/02 G05B19/19
Status	Active
Owner	Siemens Aktiengesellschaft Siemens Industry Software Limited Siemens Corporation Siemens Industry Software Inc
Simple Family	013-283-943-867-502 166-857-702-689-176 186-885-408-345-173 019-584-499-790-656 186-005-872-186-665 085-488-610-361-184 011-726-655-570-63X
CPC (with Group)	B33Y50/02 B22F10/20 B22F10/80 B22F12/90 B29C64/393 B33Y10/00 G05B19/4099 G06F30/00 G06F30/20 G06F2113/10 G06F2119/18 Y02P10/25 Y02P90/02 B29C64/20 B33Y30/00 G05B19/19 G05B2219/49007
Issuing Authority	United States Patent and Trademark Office (USPTO)
Kind	Patent Application Publication