Three-dimensional objects and their formation

Abstract

The present disclosure provides three-dimensional (3D) methods, apparatuses, software (e.g., non-transitory computer readable medium), and systems for the formation of at least one desired 3D object; comprising use of a geometric model, a physics based model, one or more markers, one or more modes, or any combination thereof. The disclosure provides reduction of deformation that may be caused by the forming process of the 3D object.

What is claimed is: 
     
         1 . A method for forming a three-dimensional object, comprising: (a) generating a simulated object using a physics model that employs an estimated alteration in the three-dimensional object present upon formation of the three-dimensional object; (b) forming a test object while employing the physics model, wherein (1) the test object comprises one or more markers, (2) the physics model comprises a plurality of modes each of which represents a plausible alteration component of the three-dimensional object present upon formation of the three-dimensional object, or (3) any combination of (1) and (2); and (c) adjusting the physics model to form an adjusted physics model, which adjusting is while employing a comparison between (i) the simulated object and (ii) an image of the test object that is formed using computer instructions, which computer instructions employ (I) a geometric model of the three-dimensional object, (II) a material property of the three-dimensional object, or (III) any combination thereof. 
     
     
         2 . The method of  claim 1 , wherein the forming comprises printing using three-dimensional printing. 
     
     
         3 . The method of  claim 1 , wherein the adjusting in (c) is a learning module. 
     
     
         4 . The method of  claim 3 , wherein the learning module comprises an inelastic response to generating the three-dimensional object. 
     
     
         5 . The method of  claim 3 , wherein the learning module comprises a learning algorithm. 
     
     
         6 . The method of  claim 1 , further comprising (d) generating the three-dimensional object using instruction employing the adjusted physics model. 
     
     
         7 . The method of  claim 6 , wherein the generated three-dimensional object is a requested three-dimensional object. 
     
     
         8 . The method of  claim 1 , wherein the comparison employs comparing at least one predicted deformation of the simulated object with at least one deformation of the test object. 
     
     
         9 . The method of  claim 1 , wherein adjusting the physics model is iterative. 
     
     
         10 . The method of  claim 1 , further comprising iteratively repeating (a), (b) and (c). 
     
     
         11 . The method of  claim 10 , wherein iteratively repeating (a), (b) and (c) is until one or more dimensions of the test object corresponds to an acceptable dimensional accuracy range relating to a requested three-dimensional object. 
     
     
         12 . The method of  claim 1 , wherein the image of the test object comprises image markers corresponding to physical markers of the test object. 
     
     
         13 . The method of  claim 1 , wherein the estimated alteration employs a predicted change of at least one characteristic of the three-dimensional object. 
     
     
         14 . The method of  claim 1 , wherein the estimated alteration employs at least one physics-based calculation. 
     
     
         15 . The method of  claim 1 , wherein the estimated alteration employs a thermo-mechanical analysis, the material property of the three-dimensional object, continuum mechanics, at least one characteristic of an energy beam, the geometric model of the three-dimensional object, or any suitable combination thereof. 
     
     
         16 . The method of  claim 1 , wherein the physics model includes modes. 
     
     
         17 . The method of  claim 16 , wherein the modes correspond to predicted elastic deformation modes of the three-dimensional object. 
     
     
         18 . A system for forming a three-dimensional object, the system comprising at least one controller configured to direct: (a) generating a simulated object using a physics model employing an estimated alteration in the three-dimensional object present upon formation of the three-dimensional object; (b) generating a test object while employing the physics model, wherein (1) the test object comprises one or more markers, (2) the physics model comprises a plurality of modes each of which representing a plausible alteration component of the three-dimensional object during the forming, or (3) any combination of (1) and (2); and (c) adjusting the physics model to form an adjusted physics model, which adjusting is while employing a comparison between (i) the simulated object and (ii) an image of the test object that is formed using instructions, which instructions employ (I) a geometric model of the three-dimensional object, (II) a material property of the three-dimensional object, or (III) any combination thereof. 
     
     
         19 . The system of  claim 18 , wherein forming the three-dimensional object comprises printing the three-dimensional object using three-dimensional printing. 
     
     
         20 . The system of  claim 18 , wherein the at least one controller is configured to direct iteratively repeating (a), (b) and (c) until one or more dimensions of the test object corresponds to an acceptable dimensional accuracy range relating to a requested three-dimensional object. 
     
     
         21 . The system of  claim 18 , wherein the system further comprises at least one sensor configured to sense one or more physical markers of the three-dimensional object, wherein the at least one controller is configured to (i) control sensing and/or (ii) use sensing data, of the one or more physical markers. 
     
     
         22 . The system of  claim 21 , wherein the at least one controller is configured to (i) control sensing and/or (ii) use sensing data, of the one or more physical markers during forming of the three-dimensional object. 
     
     
         23 . The system of  claim 18 , wherein the system further comprises at least one detector that is operationally coupled to the at least one controller, the at least one detector configured to detect as least one characteristic of the forming. 
     
     
         24 . The system of  claim 23 , wherein the at least one controller is configured to control the at least one detector and/or control one or more process parameters present upon detecting by the at least one detector. 
     
     
         25 . The system of  claim 23 , wherein the at least one detector is configured to detect a temperature during forming of the three-dimensional object, wherein the at least one controller is configured to control detection of the temperature. 
     
     
         26 . The system of  claim 25 , wherein the temperature corresponds to a temperature of the three-dimensional object.