JPWO2021021469A5 - - Google Patents

Description

In some embodiments, the methods, apparatus, systems, and computer-readable media disclosed herein relate to (i) whether one or more input variables associated with a production machine are in a correct state (e.g., a prescribed or predetermined state), ( ii ) whether one or more input variables are in an erroneous state, and (ii) what is the difference between any erroneous state of one or more input variables and the correct state of the one or more input variables. In some cases, these concerns are difficult to meet. In some embodiments, the methods, apparatus, systems, and computer-readable media disclosed herein at least partially meet these concerns.

In some embodiments, the accuracy of failure prediction in a three-dimensional object (which can, for example, affect its performance for its intended purpose) can be improved because more variables exhibit deviations from their intended values (e.g., within tolerance). For example, failure prediction accuracy can be improved because more key variables exhibit deviations from their intended values. In some embodiments, the collective deviation of the (respective) values of multiple (eg, key) variables is a better predictor of failure than the deviation of the values of a single (eg, key) variable. In some embodiments, a (e.g., smaller) deviation in the (each) value of multiple (e.g., key) variables is a better predictor of failure than a (e.g., larger) deviation in the value of a single (e.g., key) variable. Better prediction can refer to earlier prediction, more accurate prediction, and/or more reliable prediction. At least two of the values of the variables integrated to predict any failure may be given different importance (eg, weights). At least two of the values of the variables integrated to predict any failure may have (eg, substantially) the same importance (eg, weight). Criticality can be highly dependent on manufacturing machines and/or processes.

In some embodiments, the QA program illustrates (i) a model of the 3D object to be formed, (ii) layers of the 3D object that have been formed, formed, or about to be formed, and/or (iii) multiple layers of the 3D object that have been or are about to be formed. The QA program may display and/or assign identification numbers for 3D objects and/or layers of 3D objects. The QA program may display the client name, build name (eg, given by the user, eg, the client). The QA program may display the start time and estimated end time 1185, 1195 of building the 3D object. The QA program may compile an estimated finish time for building the 3D object. A QA program can be operatively coupled to and/or accept input from another program for estimation of build end times, tolerances, thresholds, and/or optimal (e.g., requested) variable values. Data used and/or output by the QA program may be encrypted. A QA program may compile the report. A report may include any of the items viewed and/or processed by the QA program. The items included in the report can be predefined. One or more items included in the report may be user-defined. The order of one or more items within the report may be predefined or user-defined. The configuration of 3D objects on the platform and/or within the printing volume (eg, material bed) can be calculated and/or displayed within the user interface pfQA program. FIG. 12 shows an example of various user interfaces. The user interface 1200 shown in the example of FIG. 12 displays a 3D object 1201 in a build volume 1202 on a platform printed in a tool named Printer1. Various identification data for the print is displayed 1203 (eg, build identification number (ID number), build name, number of layers printed out of total layers, start time and data, and end date and time). QA displays a visual timeline 1204 (indicating completion) for completion of the build. The QA program user interface (UI) indicates 1205 that attention is required. The QA program UI provides 1206 options for generating (eg, viewing) reports. The QA program UI may show any parameters related to build progress. For example, average throughput, number of interruptions, maximum interruption time, number of alerts, identification of pre-deformed material (e.g., powder), remaining pre-deformed material, powder recirculation filter status, number of layers screened, user name, user's last log, and/or QA program version. The QA program UI may have various windows, tabs, drop down menus or buttons. Any of the features displayed in the QA program UI may or may not be interactive (eg, to the user). The QA program UI may display any of the printer component/process/sensor states in prose form, visually, as an average over the total cumulative print, as an average over several layers (e.g., 1207), and/or in real-time. The US interface can indicate any status of the component/process/sensor. FIG. 12 shows an example 1207 of three monitored variables associated with a monitored item (eg, heatmap). The three sensors shown in FIG. 12 include oxygen level, recirculation filter, and residual powder. Which sensor's status is averaged over every 250 layers and shown as conforming (e.g., "in spec"), various levels of non-conforming (e.g., "warning" and "alarm"), and missing data ("no data"). FIG. 12 shows two tabs (eg, Build Progress 1209 and Build Configuration 1208) that may be toggled by the user. The build configuration tab may include the total volume of the 3D object to be built, its surface area, the total number of layers required to build the 3D object, the material from which the 3D object is built, the estimated total build time, the customer, the build file name, any version of software integrated (e.g., Flow software different from QA software), the date the file is prepared, and the specific slicing operation used (e.g., slice-to-location).

Claims (33)

A method for quality assurance in printing at least one three-dimensional object, comprising:
(a) analyzing first data collected by a first sensor to identify a first deviation from a first expected value, wherein the first sensor is configured to sense a first aspect of the printing of the at least one three-dimensional object, the first aspect comprising a first variable of the printing;
(b) analyzing second data collected by a second sensor to identify a second deviation from a second expected value, the second sensor being configured to sense a second aspect of the printing of the at least one three-dimensional object, the second sensor being different than the first sensor in sensor type and/or sensor location, the second aspect comprising a second variable of the printing;
(c) assessing the quality of said printing of said at least one three-dimensional object by considering at least (I) said first deviation and (II) said second deviation to generate a result, said result comprising a third aspect, said third aspect being different from said first aspect, said third aspect being different from said second aspect, said result comprising (i) said first data collected by said first sensor and (ii) collected by said second sensor. and integrating the second data obtained by
(d) directing a three-dimensional printer to print the at least one three-dimensional object based at least in part on the result;
method including. 2. The method of claim 1, wherein said third aspect is said printing. 3. The method of claim 2, wherein said third aspect is said printing being a monitored item. 3. The method of claim 2, wherein the third aspect is (a) a printing process or (b) the printing comprising a printing device component of the three-dimensional printer utilized in the printing process. 5. The method of claim 4, wherein the third aspect is the printing comprising printing device components including a layer distribution device, an energy source, an optical system, a gas flow system, a pressure system, a material recycling system, or a platform that supports the at least one three-dimensional object during the printing. 5. The method of claim 4, wherein the third aspect is the printing comprising a printing process comprising gas flow, gas pressure, layer distribution, target surface of the printing, build plate location, gas recycling, cleanliness of the printing atmosphere, or material recycling. 2. The method of claim 1, wherein assessing the quality of the print comprises considering at least one property of the at least one three-dimensional object, the at least one property including dimensional accuracy, material composition, porosity, material phase, crystal structure, tensile stress, strength, or surface roughness. (b) a target surface on which the pre-deformed material is transformed to print the at least one three-dimensional object; (c) a transforming agent that transforms the pre-deformed material into a transformed material for printing the at least one three-dimensional object; (d) any optical components utilized in the printing of the at least one three-dimensional object; or (e)(a). , (b), (c) and (d) in any combination. 9. The method of claim 8, wherein the first variable and/or the second variable relate to (a) a pre-deformed material for printing the at least one three-dimensional object, (b) a target surface on which the pre-deformed material is deformed to print the at least one three-dimensional object, or (c) a combination of (a) and (b). (I) the first data collected by the first sensor is collected during the printing of the at least one three-dimensional object (a) in situ, (b) in real time, or (c) in situ and in real time; (II) the second data collected by the second sensor is collected during the printing (d) in situ, (e) in real time, or (f) in situ and in real time; or (III) the first data collected by the first sensor. 2. The method of claim 1, wherein the data and the second data collected by the second sensor are collected during the printing: (g) in situ; (h) in real time; or (i) in situ and in real time. 2. The method of claim 1, wherein said printing is printing said at least one three-dimensional object comprising an elemental metal or metal alloy, and said printing is printing in an atmosphere comprising water or oxygen. 2. The method of claim 1, wherein said combining comprises assigning (i) a first weight to said first data and (ii) a second weight to said second data, said second weight being different than said first weight. 2. The method of claim 1, wherein said combining comprises assigning (i) a first weight to said first data and (ii) a second weight to said second data, said first weight and said second weight varying in response to (I) said three-dimensional printer and/or (II) said printing. 2. The method of claim 1, wherein at least one of the first aspect and the second aspect includes a device status regarding the printing of the at least one three-dimensional object, the device including a non-recirculating filter. 15. The method of claim 14, wherein the method includes assessing the status of a device with respect to the printing, the device including the powder recirculation filter. 16. The method of claim 15, wherein the at least one three-dimensional object is printed by the three-dimensional printer comprising or operably coupled to a pre-deformed material recycling system, and wherein the pre-deformed material is a powder. 2. The method of claim 1, wherein (A) sensors include the first sensor and the second sensor, the sensors include at least one sensor configured to measure a variable related to the atmosphere of the three-dimensional printer, and (B) the third aspect relates to contaminants in the atmosphere of the three-dimensional printer, or (C) a combination of (A) and (B). 18. The method of claim 17, wherein the third aspect relates to contaminants in the atmosphere of the three-dimensional printer. 19. The method of claim 18, wherein said contaminants are generated during said printing of said at least one three-dimensional object. 19. The method of claim 18, wherein the second sensor differs from the first sensor in sensor type. 19. The method of claim 18, wherein the contaminants comprise fumes, soot, dust, or dirt. 19. The method of claim 18, wherein said contaminants include materials resulting from heating, melting, evaporation, and/or other transition processes. The sensors include the first sensor and the second sensor, the sensors including the at least one sensor configured to measure the variable related to the atmosphere of the three-dimensional printer. 18. The method of claim 17. 24. The method of claim 23, wherein the at least one sensor comprises an oxygen sensor, humidity sensor, gas flow sensor, or pressure sensor. 24. The method of claim 23, wherein the second sensor differs from the first sensor in sensor type. 24. The method of claim 23, wherein the second sensor differs from the first sensor in sensor position. 2. The method of claim 1, further comprising stamping collected third data, said stamping comprising a time stamp and a location stamp, said third data collected by said first sensor and/or said second sensor. 28. The method of claim 27, wherein the at least one three-dimensional object is printed layer-by-layer, and wherein positions of the position stamps correspond to positions of layers as part of the at least one three-dimensional object. Apparatus for quality assurance in printing at least one three-dimensional object, comprising at least one controller configured to direct one or more operations of any one of claims 1 to 28. 30. The apparatus of Claim 29, wherein the at least one controller is configured to control or direct printing of one or more three-dimensional objects from at least a portion of a material bed. Computer program for execution by a computer system having one or more processors configured to perform or direct the performance of one or more operations recited in any one of claims 1 to 28 32. The computer program product of claim 31, wherein the action comprises controlling or directing the control of printing one or more three-dimensional objects by three-dimensional printing. 32. The computer program product of claim 31, wherein the one or more processors comprise or are operably coupled to a database incorporating external data, and wherein assessing the quality of the printing includes considering the external data, the external data being data collected external to the three-dimensional printer utilized in the printing of the at least one three-dimensional object.