GB2603931A - Method for handling an additively manufactured part - Google Patents

Method for handling an additively manufactured part Download PDF

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Publication number
GB2603931A
GB2603931A GB2102371.8A GB202102371A GB2603931A GB 2603931 A GB2603931 A GB 2603931A GB 202102371 A GB202102371 A GB 202102371A GB 2603931 A GB2603931 A GB 2603931A
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GB
United Kingdom
Prior art keywords
target feature
additively manufactured
manufactured part
computer
additively
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
GB2102371.8A
Other versions
GB202102371D0 (en
Inventor
Crabtree Joseph
Rybalcenko Konstantin
Gaio Andre
Evan Charlesworth Rory
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Additive Manufacturing Technologies Ltd
Original Assignee
Additive Manufacturing Technologies Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Additive Manufacturing Technologies Ltd filed Critical Additive Manufacturing Technologies Ltd
Priority to GB2102371.8A priority Critical patent/GB2603931A/en
Publication of GB202102371D0 publication Critical patent/GB202102371D0/en
Publication of GB2603931A publication Critical patent/GB2603931A/en
Pending legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—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
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/379—Handling of additively manufactured objects, e.g. using robots
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1694—Programme controls characterised by use of sensors other than normal servo-feedback from position, speed or acceleration sensors, perception control, multi-sensor controlled systems, sensor fusion
    • B25J9/1697—Vision controlled systems
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—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
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/40—Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—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
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—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
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—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
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/4097—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by using design data to control NC machines, e.g. CAD/CAM
    • G05B19/4099—Surface or curve machining, making 3D objects, e.g. desktop manufacturing
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/49—Nc machine tool, till multiple
    • G05B2219/49007—Making, forming 3-D object, model, surface
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/49—Nc machine tool, till multiple
    • G05B2219/49023—3-D printing, layer of powder, add drops of binder in layer, new powder

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Robotics (AREA)
  • Optics & Photonics (AREA)
  • Automation & Control Theory (AREA)
  • General Physics & Mathematics (AREA)
  • Human Computer Interaction (AREA)
  • Automatic Assembly (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Abstract

Method for handling an additively manufactured part 10 comprises application step wherein a target feature 16 is applied to an additively manufactured part 10, a detection step, wherein the target feature 16 applied to the additively manufactured part 10 is detected using a computer-operable detection mechanism, a control step, wherein a computer-operable actuator is controlled, via a controller, so as to engage with the target feature 16 detected in the detection step and a handling step, wherein the additively manufactured part 10 is handled by the computer operable actuator via the target feature 16 applied during the application step. The application step may comprise providing part 10 with a protrusion (54, fig. 4a), target feature 16 forming part of the protrusion (54, fig. 4a). The protrusion (54, fig. 4a) may comprise stem portion (55, fig. 4a) for mounting target feature (56, fig. 4a). The target feature 16 may be a hole. Also claimed is an additively manufactures part comprising main body with desired product profile and a target feature for detection using computer-operable detection mechanism and configured for engagement with computer-operable actuator.

Description

METHOD FOR HANDLING AN ADDITIVELY MANUFACTURED PART
FIELD
The present disclosure relates to a method and system for handling additively manufactured parts, and to a part for use with the same.
BACKGROUND
The introduction of automated systems into modern manufacturing processes has been a significant step in the manufacturing industry towards improving the delivery times and efficiency of modern production lines. For example, industries such as the automotive industry now rely heavily on automated systems in order to meet global production demands.
In order to improve efficiency, automated systems often implement computer-based detection methods to detect parts so that parts can be automatically grabbed and handled (e.g. using a robotic arm) following a build operation.
However, unlike traditional manufacturing methods, the shape and geometry of parts manufactured using additive manufacturing processes can vary greatly from one build to the next.
As such, it is very difficult for current systems to consistently and reliably detect and handle parts manufactured via additive manufacturing processes. Consequently, the obtainable delivery times and efficiency of such operations are not yet optimised.
The present disclosure aims to address at least one of these problems.
SUMMARY
According to a first aspect of the disclosure, there is provided a method for handling an additively manufactured part, the method comprising an application step, wherein a target feature is applied to an additively manufactured part, a detection step, wherein the target feature applied to said part is detected using a computer-operable detection mechanism, a control step, wherein a computer-operable actuator is controlled, via a controller, to engage with the target feature detected in the detection step and a handling step, wherein the part is handled by the computer-operable actuator, via the target feature.
Advantageously, it has been found that by applying a target feature to an additively manufactured part, by which the part can be detected and handled, it is possible to reduce handling errors typically encountered when attempting to handle additively manufactured parts.
In exemplary embodiments, the application step comprises providing a protrusion to said part, the protrusion extending outwardly from said part; wherein the target feature forms at least part of said protrusion.
Advantageously, it has been found that a protrusion can be easily applied to an additively manufactured part without requiring any significant changes to the additively manufactured part, thereby providing a quick and easy method for providing a target feature.
Furthermore, a target feature located at a protrusion can be easily handled without contacting the rest of the part, and therefore damage to the part can be better avoided.
In exemplary embodiments, the protrusion further comprises a stem portion for mounting the target feature on the additively manufactured part, and wherein the stem portion is configured so as to space the target feature away from the additively manufactured part.
Advantageously, it has been found that spacing the target feature away from the additively manufactured part via a stem can help a computer-operable detection mechanism to more reliably detect the target feature, thereby further reducing detection and handling errors.
In exemplary embodiments, a diameter of the stem portion is narrower than a diameter of the target feature.
Advantageously, it has been found that providing a stem portion having a diameter which is narrower than that of the target feature provides the target feature with a natural overhang which helps to facilitate easier handling of the part.
Furthermore, target features having a narrow stem portion are typically easier to remove from the additively manufactured part after handling.
In exemplary embodiments, the protrusion is provided in the form of a support raft.
In exemplary embodiments, the target feature is provided in the form of a hole.
Advantageously, it has been found providing a target feature, or target feature, in the form of a hole can help to facilitate more reliable handling of the part.
In exemplary embodiments, the target feature has a regular shape.
Advantageously, it has been found that target features having a regular shape can be more reliably detected by a computer-operable detection mechanism.
In exemplary embodiments, target feature has a configuration that allows the additively manufactured part to be hung from a storage rack via the target feature.
In exemplary embodiments, target feature has a configuration that allows the additively manufactured part to be hung from a storage rack via the target feature in a pre-determined orientation.
In exemplary embodiments, the handling step comprises moving the additively manufactured part and then hanging the additively manufactured part on said storage rack via the target feature.
Advantageously, configuring the target feature to allow the part to be hung via said feature helps to reduce handling errors when hanging the part, whilst also facilitating efficient storage of the part.
In exemplary embodiments, the target feature comprises a pair of divergent surfaces.
In exemplary embodiments, the target feature is V-shaped in cross-section.
In exemplary embodiments, the target feature is arched in cross-section.
Advantageously, shaping the target feature in this manner helps to ensure that the part is stored in the correct orientation without the need for further adjustment / manipulation, thereby further improving operational efficiency.
In exemplary embodiments, the method further comprises a build step, wherein the additively manufactured part is built via an additive manufacturing process.
In exemplary embodiments, the build step and the application step are performed concurrently.
Advantageously, performing the build step and application step concurrently can help to further improve process efficiency.
In exemplary embodiments, the method further comprises a modification step, wherein a build file for additively manufacturing an additively manufactured part is modified to incorporate the target feature.
Advantageously, performing the build step and application step concurrently can help to further improve process efficiency.
In exemplary embodiments, the method further comprises a removal step, wherein the target feature is removed from the additively manufactured part after the handling step.
In exemplary embodiments, the method comprises providing a plurality of additively manufactured parts, and the application step comprises applying each of said parts with a target feature, and wherein the respective target features applied to the plurality of additively manufactured parts are at least substantially identical to one another.
Advantageously, using the same target feature for a plurality of additively manufactured parts can help to further improve operational efficiency, since the computer-operable detection mechanism and actuator only need to be programmed to detect and actuate a single type of target feature.
Furthermore, it has also been found that using the same target feature for a plurality of parts can help to further reduce the occurrence of handling errors.
According to a second aspect of the disclosure, there is provided an additively manufactured part comprising a main body, the main body defining a desired product profile and a target feature configured for detection using a computer-operable detection mechanism, and configured for engagement with a computer-operable actuator and/or a storage apparatus so as to facilitate handling and/or storage of the additively manufactured part.
Advantageously, it has been found that providing a target feature by which the main body of the part can be detected and handled, it is possible to reduce handling errors typically encountered when attempting to handle additively manufactured parts.
In exemplary embodiments, the target feature does not form part of the desired product profile.
In exemplary embodiments, the additively manufactured part comprises a protrusion extending outwardly from the main body, and wherein the target feature forms at least part of said protrusion.
Advantageously, a target feature in the form of a protrusion can be easily applied to an additively manufactured part without requiring any significant changes being made to the main body of the additively manufactured part.
In exemplary embodiments, the protrusion further comprises a stem portion for mounting the target feature on the main body of the additively manufactured part, and wherein the stem portion is configured so as to space the target feature away from the main body of the additively manufactured part.
Advantageously, it has been found that spacing the target feature away from the additively manufactured part can help a computer-operable detection mechanism to even more reliably detect the target feature, thereby further reducing detection and handling errors.
In exemplary embodiments, a diameter of the stem portion is narrower than a diameter of the target feature.
Advantageously, it has been found that providing a stem portion having a diameter which is narrower than that of the target feature provides the target feature with a natural overhang which helps to facilitate easier handling of the part.
Furthermore, target features having a narrow stem portion are typically easier to remove from the additively manufactured part after handling.
In exemplary embodiments, the protrusion is provided in the form of a support raft.
In exemplary embodiments, the target feature is provided in the form of a hole.
Advantageously, it has been found providing a target feature, or target feature, in the form of a hole can help to facilitate more reliable handling of the part.
In exemplary embodiments, the target feature is integrally formed with the main body additively manufactured part.
In exemplary embodiments, the target feature has a regular shape.
Advantageously, it has been found that target features having a regular shape can be more reliably detected by a computer-operable detection mechanism.
In exemplary embodiments, the target feature has a configuration that allows the additively manufactured part to be hung in a pre-determined orientation.
Advantageously, configuring the target feature in this manner helps to ensure that the part is stored in the correct orientation without the need for further adjustment / manipulation, thereby further improving operational efficiency.
In exemplary embodiments, the target feature comprises a pair of divergent surfaces.
In exemplary embodiments, the target feature is V-shaped in cross-section.
In exemplary embodiments, the target feature is arched in cross-section.
Advantageously, shaping the target feature in this manner helps to ensure that the part is stored in the correct orientation without the need for further adjustment / manipulation, thereby further improving operational efficiency.
According to a third aspect of the disclosure, there is provided a system for handling an additively manufactured part, the system comprising a build part for applying a target feature to an additively manufactured part, a computer-operable detection mechanism configurable for detecting a target feature of an additively manufactured part, a computer-operable actuator for engaging with and handling an additively manufactured part via its respective target feature and a controller configurable for controlling the computer-operable actuator so as to engage with a target feature of an additively manufactured part, detected via the computer-operable detection mechanism, and handle the additively manufactured part via said target feature.
In exemplary embodiments, the computer-operable actuator is a robotic arm.
In exemplary embodiments, the computer-operable detection mechanism is a camera.
In exemplary embodiments, the computer-operable detection mechanism is a laser scanner.
In exemplary embodiments, the build part comprises an additive manufacturing 25 apparatus.
In exemplary embodiments, the build part is further configured to additively manufacture the additively manufactured part.
Advantageously, by allowing the build step and application step to be performed concurrently, the build part can help to further improve process efficiency.
In exemplary embodiments, the build part is configurable for modifying a build file for additively manufacturing an additively manufactured part to incorporate the target 35 feature.
Advantageously, by allowing the build step and application step to be performed concurrently, the build part can help to further improve process efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the disclosure will now be described with reference to the accompanying drawings, in which: Figure 1A illustrates a front view of an additively manufactured part according to an
embodiment of the present disclosure;
Figure 1B illustrates a perspective view of a storage rack suitable for interaction with the additively manufactured part illustrated in Figure 1A; Figure 2 illustrates a schematic view of a system for handling an additively manufactured part according to an embodiment of the present disclosure; Figure 3 illustrates a schematic flow chart of a method for handling an additively manufactured part according to an embodiment of the present disclosure.
Figure 4A illustrates a front view of an additively manufactured part according to an alternative embodiment of the present disclosure; Figure 43 illustrates a perspective view of a storage rack suitable for interaction with the additively manufactured part illustrated in Figure 4A; and Figure 4C illustrates a perspective view of an alternative storage rack suitable for interaction with the additively manufactured part illustrated in Figure 4A; Figure 5 illustrates a perspective view of an additively manufactured part according to
a further embodiment of the present disclosure;
DETAILED DESCRIPTION OF EMBODIMENT(S)
An additively manufactured part 10 according to an embodiment of the present disclosure is shown in Figure 1A.
The part 10 is made up of a main body 12 and a target feature 16.
The main body 12 defines a desired product profile of the part 10. In other words, the main body 12 of the additively manufactured part 10 defines the product which the manufacturing process ultimately wishes to obtain. For example, if the additive manufacturing process was configured for manufacturing cuboid structures, the main body 12 would define the desired cuboid structure.
The main body 12 of the additively manufactured part is formed using an additive manufacturing process and therefore exhibits a sintered structure made up of a plurality of layers.
Meanwhile, the target feature 16 is provided in addition to the main body 12 of the part 10 to facilitate detection using a computer-operable detection mechanism (see Figure 3) and to provide a feature by which the additively manufactured part 10 can be handled, for example via engagement with a computer-operable actuator, such as a robotic arm.
In the illustrated embodiment, the target feature 16 is provided in the form of a through-hole having a regular triangular shape in cross-section with said through-hole passing through a thickness of the main body 12 of the additively manufactured part 10. However, it shall be appreciated that in alternative embodiments, target features having other such cross-sectional shapes (such as a circle, square, pentagon, hexagon etc.) may be provided, as is also illustrated in Figure la.
Target features having a regular shape are particularly advantageous since it has been found that such target features can be more easily detected using computer-operable detection mechanisms, such as a camera, a laser scanner, a 3D scanner or the like. However, it shall be appreciated that irregularly shaped target features may also be used in some alternative embodiments.
Furthermore, whilst the target feature of Figure 1A is illustrated as a through-hole, it shall also be appreciated that in some embodiments, the target feature may be a blind hole which only passes through a portion of the thickness of the additively manufactured part.
The target feature 16 illustrated in Figure 1A further comprises a pair of divergent sidewalk 16a, 16b, which combined have an inverted V-shaped profile in cross-section. The pair of divergent sidewalls 16a, 16b define the apex of the triangular profile of the target feature 16.
The inverted V-shaped profile of the sidewalls 16a, 16b advantageously enables the additively manufactured part 10 to be hung in a pre-determined orientation from a corresponding storage rack.
A storage rack 20 suitable for supporting the additively manufactured part illustrated in Figure 1A is shown in Figure 1B.
The storage rack 20 has a pair of legs 21, 22 each leg having a respective base 21a, 22a at one end thereof, proximal to the surface upon which the storage rack 20 is located.
The storage rack 20 also comprises a frame section 24 extending between the respective legs 21, 22 at an opposite end to that of the bases 21a, 22b. The frame section 24 comprises a series of laterally extending spokes 26 for being received through a respective target feature 16 of an additively manufactured part 10 such that each spoke 26 can support an additively manufactured part 10 respectively.
A system 30 for handling the additively manufactured part illustrated in Figure lA shall now be described with reference to Figure 2.
The system 30 is made up of a build part 32, a detection mechanism 34, an actuator 36 and a controller 38.
The build part 32 is configured for applying the target feature 16 onto the main body 12 of the additively manufactured part 10.
In the illustrated embodiment, the build part 32 includes an additive manufacturing apparatus 32a and a computer 32b having a processor and a memory. The computer 32b is configured to store build files containing commands for instructing the additive manufacturing apparatus 32a to create a desired part 10.
The computer 32b is further configured to modify the build files stored in the computer memory, for example based on inputs from a user, to incorporate into the build files commands for instructing the additive manufacturing apparatus 32a to create an additively manufactured part 10 featuring a main body 12, corresponding to a desired product profile (as has been discussed previously) and a target feature via which the part 10 can be detected and handled.
Whilst the build part 32 of the illustrated embodiment is provided in the form of an additive manufacturing apparatus and a computer, it shall be appreciated that in other embodiments, the protrusion 14 may be applied to the additively manufactured part 10 via any other suitable method and therefore the build part 32 may be provided in any other form suitable for applying a protrusion to a part, be that via additive manufacturing processes or by any other suitable method.
The detection mechanism 34 is configured to detect the target feature 16 applied to the additively manufactured part 10 by the build part 32.
In the illustrated embodiment, the detection mechanism 34 is provided in the form of a camera. However, it shall be appreciated that in alternative embodiments, the detection mechanism may be provided as a laser scanner or via any other suitable means.
The detection mechanism 34 of the system illustrated in Figure 2 is configured to capture an image of the part 10 to be handled by the system 30. The captured image is then sent to the controller 38.
The controller 38 is provided as a computer having a memory and a processor. In the illustrated embodiment, the controller 38 is provided separately from the computer 32b of the build part 32, although it shall be appreciated that in other embodiments the same computer may be used for both the controller 38 and the build part 32.
The controller 38 stores data corresponding to one or more target features in its memory. Upon receiving a captured image from the detection mechanism 34, the controller 38 is able to interrogate its memory so as to match the image captured via the detection mechanism 34 to one of the known target features stored in its memory.
The controller 38 is also in communication with the actuator 36 such that, upon positively matching a captured image with a known target feature stored within its memory, the controller 38 is able to control said actuator 36 so as to engage with the target feature 16 detected by the detection mechanism 34 as shall be described in greater detail with reference to the method below.
In the illustrated embodiment, the actuator 36 is provided in the form of a robotic grabber arm. However, it shall be appreciated that any other suitable actuation mechanism may be used.
In the illustrated embodiment, the system 30 further comprises a storage rack, in this case the storage rack 20 illustrated in Figure 1B, for receiving the additively manufactured part 10 after it has been handled via the actuator 36. However, it shall be appreciated that in other embodiments, other storage apparatuses may be used and hence, in some embodiments, the storage rack 20 may be omitted.
A method of handling the additively manufactured part 10 illustrated in Figure 1A shall now be described with reference to Figure 3.
A first step of the aforementioned method is the application step 40 wherein the target feature 16 is applied to the additively manufactured part 10.
As has been mentioned above, when using the system 30 illustrated in Figure 2, the application step 40 comprises modifying an additive manufacturing build file such that the modified build file contains instructions for commanding the additive manufacturing apparatus 32a to build a part comprising a main body 12 and a target feature 16.
Once the modified build file has been created, it can then be sent to the additive manufacturing apparatus 32a which performs a build step wherein the additively manufactured part 10 is concurrently built and applied with the target feature 16. In other words, the part 10 is built and the target feature 16 is applied as part of the same additive manufacturing process (i.e. the part 10 and the target feature 16 are integrally formed).
Advantageously, performing the build step and application step concurrently helps to improve the efficiency of the process. However, in other embodiments, it shall be appreciated that the target feature 16 may be applied to the part 10 as a separate process after the main body 12 of the part 10 has been additively manufactured. Furthermore, it shall also be appreciated that in some embodiments, the target feature 16 may be applied via any suitable process, and therefore the target feature 16 may be applied to the main body 12 of the part 10 via processes other than additive manufacturing.
After the target feature 16 has been applied to the additively manufactured part 10 via the application step 40, a detection step 42 is performed.
During the detection step 42, the target feature 16 that has been applied to the additively manufactured part 10 is detected using the detection mechanism 34.
In the illustrated embodiment, the detection step 42 involves an image of the target feature 16 being captured via the detection mechanism 34, in this case a camera. This image is then passed to the controller 38 which interrogates the image captured by the detection mechanism 34 and matches said image with target feature data stored within the memory of the controller 38.
Upon obtaining a positive match between the target feature 16 applied to the additively manufactured part 10 and at least one piece of target data stored within the memory of the controller 38, a control step 44 is initiated by the controller 38.
In the control step 44, the actuator 36 (in this case a robotic grabber arm) is controlled via the controller 38 so as to engage with the target feature 16 detected during the detection step 42.
Once the actuator 36 is engaged with the target feature 16 of the additively manufactured part 10, the actuator 36 can then be further controlled by the controller 38 so as to handle and manipulate the part 10 as required during the handling step 46.
In the illustrated embodiment, the handling step 46 involves picking up the part 10 via the target feature 16 and hanging said part 10 from a storage rack 20 by inserting one of the plurality of spokes 26 into the corresponding target feature 16 of the part 10.
During the handling step 46, in the case where the target feature 16 is provided in the form of a hole, the actuator 36 engages the internal surfaces of the target feature 16 On this case a hole) and slides it onto a respective spoke 26 of the storage rack.
Meanwhile, in the case where the target feature 16 is provided in the form a protrusion (as will be described later with reference to Figure 4), such as a sphere, the actuator 36 engages the external surfaces of the target feature 16 to enable the part 10 to be manoeuvred.
In the illustrated embodiment, the actuator is provided in the form of a six-axis robot arm with a two-finger gripper and a corresponding guidance system which helps to track the gripper coordinates, thereby allowing the part (once targeted and grabbed) to be moved to where the spokes are located. However, in other embodiments, alternative forms of gripper, such as vacuum suction grippers or adaptive shape grippers may be used.
Once the part 10 is received on the storage rack 20, the divergent sidewalls 16a, 16b of the target feature 16 cause the spoke 26 to be received at the apex of the triangular target feature 16.
This has the effect of ensuring that the additively manufacture part 10 is hung in a predetermined orientation when placed upon the storage rack, without any further adjustment operations being required by the actuator 36.
In the illustrated embodiment, the target feature 16 is shaped so as to enable the part to hang freely from a given storage rack. However, in other embodiments, the target feature 16 may be configured to form a "snap-fit" or other suitable type of connection with the respective storage rack in order to help prevent the part 10 from swinging during storage.
The part 10 can then be left upon the storage rack 20 until it is next required.
Advantageously, it has been found that by applying a target feature to an additively manufactured pad, by which the part can be detected and handled, it is possible to reduce handling errors typically encountered when attempting to handle additively manufactured parts.
Furthermore, the process can also be repeated for a plurality of additively manufactured pads with each pad being applied with an identical target feature for detection and handling of this part.
Once storage of the part 10 is no longer required (for example prior to shipping the product out to a prospective customer), the part 10 can be removed from the storage rack 20 in substantially the same manner as has been described above.
Furthermore, whilst the aforementioned embodiments have been described with reference to an additively manufactured part 10 wherein the target feature 16 is provided in the form of a through hole, it shall be appreciated that in other embodiments, other forms of target feature may be provided.
An additively manufactured part 50 according to an alternative embodiment of the present disclosure is illustrated in Figure 4A.
As with the additively manufactured part 10 shown in Figure 1A, the part 50 illustrated in Figure 4A is made up of a main body 52, defining a desired product profile, and a target feature 56.
However, in the case of the embodiment shown in Figure 4A, the target feature 56 is formed as a solid protrusion 54 extending outwardly away from the main body 52 of the part 50, rather than as a hole.
The target feature 56 is spaced apart from the main body 52 of the part 50 via a stem portion 55 which mounts the target feature 56 to the main body 52.
Advantageously, it has been found that providing the target feature 56 spaced apart from the main body 52 of the part 50 makes the target feature 56 more easy to detect during the detection step 42 and hence handling errors can be further reduced.
In the illustrated embodiment, the protrusion 54 is applied to the main body 52 as part of the additive manufacturing process and therefore the protrusion 54 also exhibits a sintered structure made up of a plurality of layers, similar to that of the main body 52. In other words, the protrusion 54 (and the so called "target feature') are integrally formed with the main body 52 of the additively manufactured part 50.
Furthermore, since the main body 52 and the protrusion 54 are formed from the same additive manufacturing process, both the main body 52 and the protrusion 54 are formed of the same material, such as a metallic or polymeric material. However, it shall be appreciated that in other embodiments, the protrusion 54 may be applied as a separate operation, after the main body 52 has been manufactured, and therefore may be of a different structure and material to that of the main body 52.
As with the embodiment illustrated in Figure 1A, the target feature 56 is provided having a regular shape, in this case having a circular cross-sectional profile. However, it shall be appreciated that in other embodiments, the target feature may be of any other suitable shape. For example, as shown in Figure 4A, in alternative embodiments, the target feature may be provided as a hook, an arch or having a T-shaped cross-sectional profile.
The stem portion 55 has a diameter which is substantially narrower than the diameter of the target feature 56. As well as helping to reduce handling errors, it has also been found that providing a relatively narrow stem portion helps to better facilitate removal of the target feature 56 following storage, as has been described above. For example, due to the narrow nature of the stem portion 55, the target feature 56 can be easily removed from the main body 52 of the part 50 via cutting the stem portion 55 with a wire-cutting tool or the like.
A storage rack 60 suitable for supporting the addifively manufactured part illustrated in Figure 4A is also shown in Figure 4B.
As with the storage rack 20 illustrated in Figure 1 B, the storage rack 60 has a pair of legs 61, 62 each leg having a respective base 61a, 62a at one end thereof, proximal to the surface upon which the storage rack 60 is located.
The storage rack 60 also comprises a frame section 64 extending between the respective legs 61, 62 at an opposite end to that of the bases 61a, 62b. However, unlike the frame section of Figure 1B, the frame section 64 of Figure 4B comprises a body portion 65 having a series of slots 66. The slots 66 are sized so as to receive the stem portion 55 of the part 50 but are narrow enough so as to prevent passage of the target feature 56 through the respective slots 66.
As such, upon the stem portion 55 of the part 50 being received within one of the slots 66, the target feature 56 will urge against an upper surface 67 of the main body 65 thereby enabling the part 50 to hang from the rack 60 in a pre-determined orientation.
A storage rack 70 according to a further alternative embodiment for use with an additively manufactured part having a hook-shaped target feature is also illustrated in Figure 4C.
The storage rack 70 is substantially the same as the storage rack 20 illustrated in Figure 1B and so common parts have been designated with corresponding reference numerals having the prefix "T. However, unlike in the storage rack 20, the frame section 74 of the storage rack 70 is provided as a continuous loop section 76 extending around the storage rack 70 upon which a respective hook-shaped target feature of the part can be secured so as to facilitate hanging/storage of the part in a pre-determined orientation.
The additively manufactured part 50 can be handled and stored in substantially the same way as has been described for the embodiment illustrated in Figure 1 and so, for the sake of conciseness, the handling and storing operation used for this embodiment shall not be described in details.
However, it shall be appreciated that whilst the target hole of the embodiment illustrated Figure 1 provides a substantially permanent feature of the additively manufactured part 10, in some embodiments, the protrusion 54 and target feature 56 of the additively manufactured part 50 illustrated in Figure 4 may be removed from the part 50, for example via a cutting operation, during a removal step (following the handling! storage operation) so as to obtain the desired final product as defined by the main body 52 of the part 50.
An additively manufactured part 80 according to a further embodiment of the present
disclosure is also illustrated in Figure 5.
As with the additively manufactured parts shown in Figure 4, the part 80 illustrated in Figure 5 is made up of a main body 82, defining a desired product profile, and a target feature 86, which is also formed as a solid protrusion 84 extending outwardly away from the main body 82 of the part 80.
However, unlike the embodiment of Figure 4 wherein the protrusion 54 is provided in the form of a hanging feature to enable the part to be suspended from a support rack during storage, in the embodiment illustrated in Figure 5, the protrusion 84 is provided in the form of a support raft extending outwardly from a bottom surface of the part 80.
The feature of a support raft is beneficial since it enables the part 80 to be stored in a stable manner without the need for specific storing apparatus, such as storage racks.
In the embodiment illustrated in Figure 5, the support raft is provided in the form of a cuboid structure having a plurality of struts. The support raft also features a pair of cross-struts 88a, 88b extending diagonally across the cuboid structure for supporting the additively manufacture part 80 thereon. However, it shall be appreciated that in other embodiments, the support raft may be of any other suitable configuration.
In the illustrated embodiment, the support raft is applied to the main body 82 as part of the additive manufacturing process and therefore the support raft also exhibits a sintered structure made up of a plurality of layers, similar to that of the main body 82. In other words, the support raft is integrally formed with the main body 82 of the additively manufactured pad 80.
Furthermore, since the main body 82 and the support raft are formed from the same additive manufacturing process, both the main body 82 and the support raft (i.e. the protrusion 84) are formed of the same material, such as a metallic or polymeric material. However, it shall be appreciated that in other embodiments, the support raft may be applied as a separate operation, after the main body 82 has been manufactured, and therefore may be of a different structure and material to that of the main body 82.
The additively manufactured pad 80 can then be detected and handled via the support raft in substantially the same way as has been described for the embodiment illustrated in Figure 4, although it shall be appreciated that the storage rack, and associated method steps associated therewith, may be omitted for this embodiment.
Although the disclosure has been described above with reference to one or more preferred embodiments, it will be appreciated that various changes or modifications may be made without departing from the scope of the invention as defined in the appended claims.

Claims (25)

  1. CLAIMS1. A method for handling an additively manufactured part, the method comprising: an application step, wherein a target feature is applied to an additively manufactured part; a detection step, wherein the target feature applied to said part is detected using a computer-operable detection mechanism; a control step, wherein a computer-operable actuator is controlled, via a controller, to engage with the target feature detected in the detection step; and a handling step, wherein the part is handled by the computer-operable actuator, via the target feature.
  2. 2. The method according to claim 1, wherein the application step comprises providing said part with a protrusion, the protrusion extending outwardly from said part and wherein the target feature forms at least part of said protrusion.
  3. 3. The method according to claim 2, wherein the protrusion further comprises a stem portion for mounting the target feature on the additively manufactured part, and wherein the stem portion is configured so as to space the target feature away from the additively manufactured part.
  4. 4. The method according to claim 3, wherein a diameter of the stem portion is narrower than a diameter of the target feature.
  5. 5. The method according to claim 1, wherein the target feature is provided in the form of a hole.
  6. 6. The method according to any preceding claim, wherein the target feature has a regular shape. 30
  7. 7. The method according to any preceding claim, wherein the target feature has a configuration that allows the additively manufactured part to be hung from a storage rack via the target feature, optionally in a pre-determined orientation, and wherein the handling step comprises moving the additively manufactured part and then hanging the additively manufactured part on said storage rack via the target feature.
  8. 8. The method according to claim 7, wherein the target feature comprises a pair of divergent surfaces, and optionally wherein the target feature is V-shaped or arched in cross-section.
  9. 9. The method according to any preceding claim, further comprising a build step, wherein the additively manufactured part is built via an additive manufacturing process, and wherein the build step and the application step are performed concurrently.
  10. 10. The method according to claim 9, further comprising a modification step, wherein a build file for additively manufacturing an additively manufactured part is modified to incorporate the target feature.
  11. 11. The method according to any preceding claim, further comprising a removal step, wherein the target feature is removed from the additively manufactured part after the handling step.
  12. 12. The method according to any preceding claim, wherein the method comprises providing a plurality of additively manufactured parts, and the application step comprises applying each of said parts with a target feature, and wherein the respective target features applied to the plurality of additively manufactured parts are substantially identical to one another.
  13. 13. An additively manufactured part comprising: a main body, the main body defining a desired product profile; and a target feature configured for detection using a computer-operable detection mechanism, and configured for engagement with a computer-operable actuator and/or a storage apparatus so as to facilitate handling and/or storage of the additively manufactured part.
  14. 14. The part according to claim 13, wherein the target feature does not form part of the desired product profile.
  15. 15. The part according to claim 13 or 14, wherein the additively manufactured part comprises a protrusion extending outwardly from the main body, and wherein the target feature forms at least part of said protrusion.
  16. 16. The part according to claim 15, wherein the protrusion further comprises a stem portion for mounting the target feature on the main body of the additively manufactured part, and wherein the stem portion is configured so as to space the target feature away from the main body of the additively manufactured part.
  17. 17. The part according to claim 16, wherein a diameter of the stem portion is narrower than a diameter of the target feature.
  18. 18. The part according to claim 13, wherein the target feature is provided in the form of a hole.
  19. 19. The part according to any of claims 13 to 18, wherein the target feature is integrally formed with the main body of the additively manufactured part.
  20. 20. The part according to any of claims 13 to 19, wherein the target feature has a regular shape.
  21. 21. The part according to any of claims 13 to 20, wherein the target feature has a configuration that allows the additively manufactured part to be hung in a pre-determined orientation.
  22. 22. The part according to claim 21, wherein the target feature comprises a pair of divergent surfaces, and optionally wherein the target feature is V-shaped or arched in cross-section.
  23. 23. A system for handling an additively manufactured part, the system comprising: a build part for applying a target feature to an additively manufactured part; a computer-operable detection mechanism (e.g. a camera) configurable for detecting a target feature of an additively manufactured part; a computer-operable actuator (e.g. a robotic arm) for engaging with and handling an additively manufactured part via its respective target feature; and a controller configurable for controlling the computer-operable actuator so as to engage with a target feature of an additively manufactured part, detected via the computer-operable detection mechanism, and handle the additively manufactured part via said target feature.
  24. 24. The system according to claim 23, wherein the build part comprises an additive manufacturing apparatus, and preferably wherein the build part is further configured to additively manufacture an additively manufactured part.
  25. 25. The system according to claim 24, wherein the build part is configurable for modifying a build file for additively manufacturing an additively manufactured part to incorporate the target feature.
GB2102371.8A 2021-02-19 2021-02-19 Method for handling an additively manufactured part Pending GB2603931A (en)

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CN110281231A (en) * 2019-03-01 2019-09-27 浙江大学 The mobile robot 3D vision grasping means of unmanned FDM increasing material manufacturing
EP3584042A2 (en) * 2018-06-17 2019-12-25 Robotic Materials, Inc. Systems, devices, components, and methods for a compact robotic gripper with palm-mounted sensing, grasping, and computing devices and components

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US20120113439A1 (en) * 2007-07-18 2012-05-10 Voxeljet Technology Method for producing three-dimensional components
EP2537642A1 (en) * 2011-06-23 2012-12-26 Raytheon BBN Technologies Corp. Robot fabricator
US20160332299A1 (en) * 2015-05-13 2016-11-17 Fanuc Corporation Object pick-up system and method for picking up stacked objects
EP3584042A2 (en) * 2018-06-17 2019-12-25 Robotic Materials, Inc. Systems, devices, components, and methods for a compact robotic gripper with palm-mounted sensing, grasping, and computing devices and components
CN109146939A (en) * 2018-09-07 2019-01-04 中科新松有限公司 A kind of generation method and system of workpiece grabbing template
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