Following a build operation to generate one or more printed objects in a three-dimensional (3D) printer, the printed objects may be subjected to post-processing steps. In powder-based 3D printing systems, for example, a post-processing step may include removal of any non-solidified powder that does not form part of a 3D printed object.
In an example of the disclosure, the process of producing a 3D-printed object to a particular specification may include: (i) part and build preparation; (ii) 3D printing; and (iii) post-processing. During the part and build preparation, a digital model of each object to be printed, comprising object model data representing the object, may be generated or received by a pre-printing application. The object model data can define one or multiple 3D geometry models and/or 3D transform matrices including an object model which can position an object to be printed in a 3D printer's printable area. The object model data is in a format that can be read and interpreted by a 3D printer which can carry out a 3D printing build operation.
The object model data may be received by the 3D printer. The 3D printer may comprise a controller to generate printer control data comprising build data based at least in part on the received object model data relating to the object. The printer control data may further comprise instructions to cause the 3D printer to print the build data.
The controller may be a programmable logic device (PLD) or other computing device that can carry out instructions. The controller may include multiple processing elements that are integrated in a single device or distributed across devices.
In powder-based 3D printing, after a 3D build is completed, a build chamber may include a plurality of 3D objects, formed from build material solidified by the 3D printer, along with non-solidified build powder from the build operation. In order to remove the non-solidified powder, a post-processing operation may be performed on the build chamber by a post-processing apparatus. In one example, the post-processing apparatus may remove only the non-solidified powder. In some instances, there may be adverse effects on the 3D objects during post-processing. One adverse effect may, in one example, be caused by openings in the post-processing apparatus, where a 3D object may be unintentionally extracted from the build chamber along with non-solidified powder or could be damaged if a small part of a larger object is caught in an opening. For example, an opening may be a hole or other orifice in the post-processing apparatus through which the non-solidified powder that remains in the build chamber can be removed. In another example, a post-processing apparatus may process a 3D object after printing and the post-processing process may unintentionally damage some kinds of objects or portions on objects, for example, such as objects or portions of objects below a certain size, and objects that have fragile features.
In an example, the post-processing operation is a vacuum operation including a post-processing apparatus that is a vacuum cleaner having a mesh with holes in it through which non-solidified powder from the build chamber may be extracted. In other examples, the post-processing apparatus is a vibrating platform having a mesh on which the build is positioned and through which non-solidified powder may be extracted. Other post-processing operations may include, for example, powder automatic reclaim in which powder is to be automatically extracted from a build chamber, and fast cooling which creates conditions that may adversely affect small objects. Other examples of post-processing operations may include bead blasting, or chemical polishing.
Examples disclosed relate to systems and methods for obtaining geometry data relating to a geometry of all or part of an object or plurality of objects to be 3D printed in a pre-printing operation. Object model data defining an object to be printed by a 3D printer may be obtained. Data relating to the geometry of the object to be printed can be automatically obtained in a pre-printing operation. A comparison of the geometry data with a predetermined threshold can be made and it can be estimated whether it is likely that the object will or will not be adversely affected in a post-processing operation due to its geometry. The geometry may include the size of the object or the size of a portion of the object. In examples, the adverse effect may include passing through an opening of the post-processing apparatus or being damaged by a post-processing apparatus during a post-processing operation due to the geometry information of the object and data relating to the post-processing apparatus. If it is likely that the one of the plurality of objects will pass through the opening or be damaged, the printer control data can be modified to cause an alert so that a user can decide whether or not to proceed with a print job and/or the printer control data can be modified to reduce the likelihood that the object will pass through the opening or be damaged. In an example, the reduction in the likelihood that the object will pass through the opening or be damaged can be achieved by adding a modification to the object. The modified printer control data may be automatically generated in an efficient and reliable manner.
The received object model data may define at least an object to be printed by the 3D printer. In some examples, the object model data may include a plurality of objects to be printed. The objects are to be printed in a build chamber of a 3D printer. To assist in the preparation of the build, the object model data may be modified to include a build envelope within which objects to be printed are to be arranged. The build envelope may, in one example, closely resemble the size and configuration of the printable area in the build chamber. The objects and the build envelope may be represented on a graphical user interface such as a display screen. The objects may be movable within the build envelope to allow re-configuration of the objects such that objects may be rearranged to fit inside the build envelope. Once re-configured, the object model data can be packed and sent to the printer. The printer generates printer control data that may be based on the object model data. For generating the object model data, there can be different criteria to optimise different aspects for efficient and reliable printing. This may include packing density of the objects, distance between objects or the like.
According to examples herein, a controller associated with a 3D printer may determine or estimate whether any of the objects that are to be generated on the basis of the object model data are likely to be adversely affected during a post-processing operation, for example, passing through an opening in a post-processing apparatus or being damaged in some other manner.
In an example where the adverse effect is passing through an opening in a post-processing apparatus, the opening may be a hole in the post-processing apparatus such as a vacuum cleaner that has a plurality of holes which can receive particulate therethrough such as build powder using a suction mechanism. The holes may be on a mesh that is provided in a hose of a vacuum cleaner. Each of the holes in the mesh may be of a size that is large enough to allow non-solidified powder from, for example, a build chamber to fit through the hole and to be extracted from the build chamber. Data relating to the size of the holes in the mesh of the vacuum cleaner can be stored. The data may include the cross sectional size of the hole such as the diameter and area of the hole cross section. In one example, the size data may be manually entered through manual data entry. If all the holes are not of the same size, the largest hole size data or other data that can represent the size of the largest hole in the post-processing apparatus may be obtained. In particular, the cross-sectional threshold size xV of the holes can be predetermined prior to printing and stored in an internal configuration file. The cross-sectional threshold size xV may be a form of data that represents configuration parameters of the post-processing apparatus. The cross-sectional threshold size xV may be represented, in one example, as a length value of a diameter in mm and/or an area value of a surface in mm2.
A printing controller may receive the information relating to the objects to be printed and obtain data relating to the post-processing apparatus which in an example is a size of an opening in a vacuum cleaner apparatus. A determination can then be automatically made relating to object geometry data of the objects to be printed. A detection that an object will be adversely affected during a post-processing operation based on the geometry data may be made. In one example, the detection may be if an object will pass through the opening in the post-processing apparatus. The detection may be affirmative if the size of the object in the pre-printing application is smaller than the opening in the post-processing apparatus such as a vacuum cleaner to be used during post-processing in which case the object may be classified as a small object. In one example, this may be achieved by determining whether the model size and/or shape of the object will be smaller than the cross sectional size xV of the holes.
Once a detection that an object will be adversely affected during a post-processing operation based on the geometry data is carried out for all the objects to be printed, a list of objects including a classification of the size of the objects may be generated including a first group of objects that are objects that may be adversely affected by a post-processing apparatus and a second group of objects that include the rest of the objects i.e. those that may not be adversely affected by a post-processing apparatus. The list may be displayed on a display unit, for example, of a printer and the objects in each group may be highlighted on the display unit and/or selectable by a user.
If it is detected that one or a plurality of the objects is a an object that may be adversely affected by a post-processing apparatus which in the example that the post-processing apparatus is one with holes to receive non-solidified powder is that the object is smaller than the holes of the post-processing apparatus, the print control data may be modified to prevent the object passing through the hole.
In an example, the print control data may be modified by automatically adding a structure to the object model data of an identified object to create a modified object comprising the structure and at least one or all of the objects in the first group, the modified object having a geometry, such as a size, that will not be adversely affected by a post-processing apparatus during a post-processing operation. The structure may be a digital representation of a predetermined structure that is automatically generated and suggested by the printer and/or be digitally created by a user in the printer.
In an example, the structure may be a protective housing or cage or frame that surrounds some or all the objects that are small enough to pass through the hole in the post-processing apparatus or small enough to be damaged by some other process, such as chemical polishing. The structure may partially surround the objects but to a sufficient extent to keep the objects within the structure and to prevent the object from being adversely affected by a post-processing apparatus during a post-processing operation. The modified object that is created may include at least one or all of the objects from the first group and the structure. The modified object may be of a different geometry to each object in the first group such that the modified object will not be adversely affected by a post-processing apparatus during a post-processing operation. In an example where the post-processing apparatus includes holes to receive and extract powder from a build chamber, the modified object will be of a larger size, or will have a geometry, such that it will not pass through the holes in the post-processing apparatus.
In another example, the structure comprises a removable part to connect to an object in the first group. The removable part may be one or a plurality of connectors such as sprues to releasably connect at least two of the objects in the first group together. Alternatively, at least one object in the first group may be connected with a larger object such as one in the second group, connected to another automatically generated object, or more than two objects may be connected together.
With reference to
The controller 110 of the system 100 may comprise a data input/output interface unit 111 to receive input data from external components, for example, user input devices (not shown) to allow a user to interact with the system 100. The unit 111 may also output data from the controller 110 to other external components, for example, a display unit (not shown).
The controller 110 may further comprise a processor 112 to manage all the components within the controller 110, and process all data flow between the components within the controller 110. The processor may be any of a central processing unit, a semiconductor-based microprocessor, an application specific integrated circuit (ASIC), and/or other device suitable for retrieval and execution of instructions.
The controller 110 may further comprise a storage or memory unit 120 to store any data or instructions which may need to be accessed by, for example, the processor 112. The memory unit 120 may be any form of storage device capable of storing executable instructions, such as a non-transient computer readable medium, for example Random Access Memory (RAM), Electrically-Erasable Programmable Read-Only Memory (EEPROM), a storage drive, an optical disc, or the like.
In one example, the memory unit 120 includes instructions such as instructions 121 to identify a first object to be three-dimensionally printed, instructions 122 to obtain geometry data relating to a geometry of all or part of the first object, instructions 123 to compare the geometry data with a predetermined threshold, and instructions 124 to determine whether the first object will or will not be adversely affected by a post-processing apparatus that will be used to process the object during a post-processing operation based on the comparison. If the determination is negative, the controller may analyse another object and carry out the determination for the other object. Printer control data may be modified on the basis of the determination and the modified printer model data may be stored. A 3D printer 130 may be connected to the controller 110 in that it may be incorporated into a 3D printer or associated with the 3D printer. The controller 110 may control aspects of the 3D printer 130. In one example, the printer control data is provided to the printer 130 to cause the printer 130 to carry out a 3D printing operation.
In addition, printer control data comprising build data based at least in part on object model data relating to the first object may be generated by the controller 110. If the determination at 204 is that the first object will likely be adversely affected by a post-processing apparatus that will be used to process the first object during a post-processing operation of the post-processing apparatus, the controller 110 may cause generation of an alert on the basis of the determination. The alert may be a warning that one or more objects are likely to be adversely affected by a post-processing apparatus during a post-processing operation. The alert may identify the particular object or objects that will likely be adversely affected. In an example, the alert could be a visual prompt on a display device, for example, of the 3D printer 130 and/or audible prompt from the 3D printer 130.
In another example, if the determination at 204 is that the first object will likely be adversely affected by a post-processing apparatus that will be used to process the first object during a post-processing operation of the post-processing apparatus, the controller 110 may cause the controller to generate modification data proposing a modification of the first object to prevent it from being adversely affected by the post-processing apparatus that will be used to process the object during a post-processing operation. The modification may be adding a structure such as a protective cage around the first object to surround the first object or a connector to connect to the first object. The combination of the structure and the first object may be of a different geometry to the first object so as not to be adversely affected by the post-processing apparatus during the post-processing.
Referring to
xi≤xV
where xi is value representing as estimate of the cross sectional geometry of part of the object and xV is the predetermined threshold that in one example may be an approximation of the cross sectional geometry of an opening in a post-processing apparatus. The geometry data xi as obtained in 304 of
In another example, the method 300 may be performed without 302 or 303 in which case the analysis in 304 is performed for each face of the bounding box rather than only the smallest area face and each of the slices for each face are compared to the predetermined threshold xV.
Other ways of obtaining geometry data may be used in other examples. In alternative examples, the controller 110 may receive input geometry data from a user, or the controller 110 may receive the geometry data from a predetermined location in its internal memory or through accessing the data from another external location.
The controller 110 may change the object representation and modify the printer control data by adding a structure 560 that may surround the first object 510 and second object 520. This may create modified object 570 that is of size that will not be adversely affected by a post-processing apparatus during a post-processing operation. In an example, the geometry of the modified object 570 may be such that it will not pass through the opening 540 of the post-processing apparatus 550 shown in
In some examples, the structure 560 may be a digital representation of a predetermined structure that is automatically generated and suggested by a printing application on the printer and/or be digitally created by a user in the printing application.
In an example, the structure may be a protective housing or cage or frame that encapsulates some or all the objects that are small enough to be adversely affected by a post-processing apparatus during a post-processing operation.
With reference to
After the modified object 590 has been generated, the modified printer control data can be sent to the 3D printer such as the 3D printer 130 of
In another example method 600 as shown in
In addition to the examples described in detail above, the skilled person will recognize that various features described herein can be modified and/or combined with additional features, and the resulting additional examples can be implemented without departing from the scope of the system of the present disclosure, as this specification merely sets forth some of the many possible example configurations and implementations for the claimed solution.
Filing Document | Filing Date | Country | Kind |
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PCT/US2019/043956 | 7/29/2019 | WO | 00 |