Systems and methods for calibration feedback for additive manufacturing

Abstract

A camera assembly is employed in additive manufacturing to improve the fidelity of a printed object. The camera may scan the surface of a build plate of a 3D printer and an object as it is being printed to generate image data. The image data is processed to detect errors in the build plate or printed object. The printer compensates for the detected errors, which can including modifying the printer configuration and/or modifying the instructions for printing a given object. Using the updated configuration, subsequent objects may then be printed, under a corrected process, to produce an object with fidelity to an original object model.

1 . A method for additive manufacturing of three-dimensional metal objects, the method comprising:
 printing a plurality of layers to form an object on a print surface, wherein the plurality of layers are printed layer-by-layer;   scanning each of the plurality of layers to obtain scan data for each of the plurality of layers;   generating a map based on the scan data of each of the plurality of layers;   determining whether one or more defects exist based on the map;   changing a print configuration if it is determined that the one or more defects exist; and   printing a subsequent object using the changed print configuration.   
     
     
         2 . The method according to claim  23 , wherein changing the print configuration includes changing at least one of a toolpath of a print head of a printer or a flow rate of a build material deposited by the print head. 
     
     
         3 . The method according to claim  23 , wherein determining whether one or more defects of the printed object exist includes comparing a model of the object with the map of the printed object. 
     
     
         4 . The method according to claim  25 , further comprising modifying a geometry of the model of the object if the one or more defects exist. 
     
     
         5 . The method according to claim  23 , wherein determining whether one or more defects of the printed object exist includes comparing the scan data for each of the plurality of layers in the map to each corresponding layer of a model of the object. 
     
     
         6 . The method according to claim  23 , further comprising generating print parameters defining geometry of the printed object with offsets to a model of the object. 
     
     
         7 . The method according to claim  23 , wherein the one or more defects include a discrepancy between a tool path of a print head used to print the object and the printed object. 
     
     
         8 . A method of printing an object, comprising:
 printing a first object at a 3D printer based on an initial model of an object;   scanning a plurality of layers of the first object concurrently with the printing to generate image data of the first object;   detecting deviations between the image data and the initial model;   updating print parameters of the object based on an initial model of the object and the image data, the print parameters defining printed geometry of the object with modifications to the initial model based on the detected deviations; and   printing a second object based on the print parameters.   
     
     
         9 . The method of  claim 8 , wherein the scanning includes capturing at least one photograph of the object via a camera coupled to a printer head. 
     
     
         10 . The method of  claim 9 , wherein the at least one photograph includes a plurality of photographs, and further comprising stitching together the plurality of photographs to generate the image of the object. 
     
     
         11 . The method of  claim 10 , further comprising:
 moving the camera and printer head through a plurality of distinct locations above the build plate; and   capturing each of the plurality of photographs at a respective one of the plurality of locations.   
     
     
         12 . The method of  claim 8 , wherein the scanning includes capturing photographs of a plurality of cross-sectional layers of the first object concurrently with the printing of the first object, the image data incorporating the photographs. 
     
     
         13 . The method of  claim 12 , wherein updating the print parameters includes modifying the geometry of a representation of the object based on deviations between the initial model and the photographs of the plurality of cross-sectional layers of the first object. 
     
     
         14 . The method of  claim 8 , wherein updating the print parameters includes generating a correction tool path for a print head based on the detected deviations. 
     
     
         15 . The method of  claim 14 , wherein printing the second object includes controlling the print head to print the second object based on the correction tool path. 
     
     
         16 . The method of  claim 14 , wherein printing the second object includes controlling material deposition flow rate based on the correction tool path. 
     
     
         17 . The method of  claim 14 , wherein printing the first object includes:
 printing an initial portion of the first object according to an initial tool path; and   printing a successive portion of the first object according to the correction tool path.   
     
     
         18 . The method of  claim 8 , wherein updating print parameters includes generating a correction model of the object, the correction model defining the printed geometry of the object with modifications to the initial model based on the detected deviations. 
     
     
         19 . A system for printing objects, comprising:
 a build chamber;   a printer head configured to print objects within the build chamber;   a camera mounted to the printer head and configured to capture images within the build chamber; and   a controller configured to 1) control the camera to scan a plurality of layers of a first object concurrently with printing of the first object to generate image data of the first object, 2) detecting deviations between the image data and an initial model of the object, and 3) update print parameters of the object based on an initial model of the object and the image data, the print parameters defining printed geometry of the object with modifications to the initial model based on the detected deviations.   
     
     
         20 . The system of  claim 19 , wherein the scan includes capturing at least one photograph of the object via the camera.