WO2019051048A1 - System and method for detecting defects in three-dimensional printed parts - Google Patents
System and method for detecting defects in three-dimensional printed parts Download PDFInfo
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- WO2019051048A1 WO2019051048A1 PCT/US2018/049696 US2018049696W WO2019051048A1 WO 2019051048 A1 WO2019051048 A1 WO 2019051048A1 US 2018049696 W US2018049696 W US 2018049696W WO 2019051048 A1 WO2019051048 A1 WO 2019051048A1
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- 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
- B33Y10/00—Processes of additive manufacturing
-
- 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
- B29C64/386—Data acquisition or data processing for additive manufacturing
-
- 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
- B33Y70/00—Materials specially adapted for additive manufacturing
- B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
Definitions
- Embodiments relate to three-dimensional printing.
- Three-dimensional (3D) printing may refer to the process of creating a 3D structure under computer control. During 3D printing, defects may be formed in the final 3D printed structure.
- one embodiment provides a method of detecting defects in a three- dimensional printed part.
- the method includes incorporating nanoparticles within a polymer host matrix.
- the method further includes analyzing an optical response of the nanoparticles and determining a defect based on the optical response.
- Fig. 1 is a flowchart illustrating a process of three-dimensional printing according to some embodiments.
- Fig. 2 is a flowchart illustrating a process for synthesizing nanoparticles according to some embodiments.
- Fig. 3 is a chart illustrating an absorbance spectrum according to some embodiments.
- Fig. 4 is a flowchart illustrating a process for fabricating filament according to some embodiments.
- Fig. 5 is a top view of a plurality of three-dimensional printed parts according to some embodiments.
- Fig. 6 is a flowchart illustrating a process for monitoring a material state of a three-dimensional printed part according to some embodiments.
- Fig. 7 is a chart illustrating absorbance spectra according to some embodiments.
- Fig. 8 is a chart illustrating a linear fit of optical properties according to some embodiments.
- Fig. 9 is a chart illustrating absorbance spectra according to some embodiments.
- Fig. 10 is a chart illustrating a linear fit of optical properties according to some embodiments.
- Fig. 11 is a chart illustrating a comparison of the linear fits of Figs. 8 and 10 according to some embodiments.
- FIG. 12 is a flowchart illustrating a process for determining a defect of a three- dimensional printed part according to some embodiments.
- This application discloses a material state diagnostic methodology for additively manufactured parts and materials based on the optical response of nanoparticles and quantum dots.
- Embedded within a polymer host matrix for example, polylactic acid (PLA), acrylonitrile styrene (ABS), poly(methyl methacrylate) (PMMA), polycarbonate (PC), polyvinyl alcohol (PVA), polyvinylpyrrolidone (PVP), etc.
- the optical response of nanoparticles, or nanomaterials for example, gold, silver, titanium dioxide, copper, cadmium selenide quantum dots, etc.
- the methodology to incorporate nanoparticles and quantum dots within filament may be compatible with stock three-dimensional (3D) printers to print and manufacture materials capable of providing an indication of the material state in real time based on the unique optical response of the embedded nanoparticles alone.
- a number of missing print layers in 3D printed parts and materials may be detected through the inclusion of nanoparticles within a host matrix.
- optical properties for example, absorbance intensities
- the number of layers missing in 3D printed parts may be determined based on a relationship between optical properties and film thickness, or total number of print layers.
- Embodiments disclosed may also be used to monitor a material state of 3D printed parts as the parts are exposed to external loads and stimuli in the intended applications of the 3D printed part(s). As such, not only can 3D printed materials be monitored for defects following printing (for quality control/validation and verification purposes), but also when the as printed parts are in service and exposed to external loads.
- Fig. 1 is a flowchart illustrating a process, or operation, 100 of three-dimensional (3D) printing according to some embodiments. It should be understood that the order of the steps disclosed in process 100 could vary. Additional steps may also be added to the control sequence and not all of the steps may be required.
- a part for example, parts 500a- 500n illustrated in Fig. S
- CAD computer aided design
- block 105 The CAD design part is converted to an appropriate file for printing
- the part is then printed using a material (for example, plastic, metal, polymer composite, etc.) (block 115).
- nanoparticles for example, dodecanethiol stabilized gold nanoparticles (AuNPs)
- AuNPs dodecanethiol stabilized gold nanoparticles
- other nanoparticles for example, silver nanoparticles, titanium dioxide nanoparticles, etc.
- Fig. 2 is a flowchart illustrating a process, or operation, 200 for synthesizing nanoparticles according to some embodiments. It should be understood that the order of the steps disclosed in process 200 could vary. Additional steps may also be added to the control sequence and not all of the steps may be required. Furthermore, it should be noted that although process 200 describes synthesizing gold nanoparticles, process 200 may be used to synthesize nanoparticles formed of other materials.
- a precursor is prepared through a dropwise addition of triphenylphosphine (for example, approximately 3.6 mmol) to (for example, approximately 1.8 mmol) in ethanol (for example, approximately S mL) (block 20S).
- the mixture may be observed to change from a yellow color to white.
- the resulting solution may then be filtered and washed (block 210).
- the solution is filtered and washed in ethanol and precipitated from acetone/THF (for example, 1 : 1 by volume).
- the resultant powder may then be recrystallized to obtain Au(PPh3)Cl (block 215).
- the gold nanoparticles may then be synthesized by dissolving Au(PPh 3 )Cl (for example, approximately 0.25 mmol) and approximately 125 uL of dodecanethiol in dry toluene (for example, approximately 20 mL) (block 220).
- the resulting mixture may be heated to a predetermined temperature (for example, approximately 50°C) (block 225).
- tert-butyl amine borane complex for example, approximately 2.5 mmol
- the solution may change from clear to a purple color. In some embodiments, such a color change may indicate the formation of gold nanoparticles.
- the gold nanoparticles may be precipitated in cold ethanol and centrifuged for a predetermined time (for example, approximately fifteen minutes) at a predetermined speed (for example, approximately 5 krpm) (block 235). The gold nanoparticles may then be washed one or more times (block 240). In some embodiments, the gold nanoparticles are washed with acetone via centrifugation for a predetermined time period (for example, approximately fifteen minutes) at a predetermined speed (for example, approximately 5 krpm). The resultant gold nanoparticles may then be redissolved in toluene (block 245). [0028] Fig.
- the gold nanoparticles display a single, monotonic absorbance having a maximum peak occurring at approximately 513 nm.
- the gold particles have a diameter of approximately 7.3 nm.
- Fig. 4 is a flowchart illustrating a process, or operation, 400 for fabricating filament according to some embodiments. It should be understood that the order of the steps disclosed in process 400 could vary. Additional steps may also be added to the control sequence and not all of the steps may be required.
- a key consideration for functionalized filament fabrication includes an evaluation of miscibility between the selected polymer- nanoparticle system (405 and 410). In order to assess miscibility, Hildebrand solubility parameters may be used to provide an indication of how likely a solute and solvent are to mix and combine and offers a useful approximation for measuring polymer-nanoparticle interactions.
- polylatctic acid (PL A) pellets are dissolved in dichloromethane (DCM) (block 405).
- the PLA pellets may be dissolved in other solvents, for example, but not limited to Toluene, Acetone, Ethanol, Methanol, Chloroform, Benzene, and Tetrahydrofuran (THF).
- THF Tetrahydrofuran
- the gold nanoparticles suspended in toluene may be added to the dissolved PLA pellets at a desired weight percent (for example, approximately 0.1% w/w AuNP/PLA).
- the PLA/AuNP mixtures may men be dried (block 415). In some embodiments, drying of the PLA/AuNP mixture may remove excess DCM. In some embodiments, drying of the PLA/AuNP mixture includes drying at a predetermined temperature (for example, approximately 20°C to approximately 25°C, approximately 100°C, and/or a combination of approximately 20°C to approximately 25°C and approximately 100°C). The PLA/AuNP mixture may then be extruded and spooled (block 420).
- Fig. 5 is a top view of a plurality of parts, or structures, 500 printed using PLA/AuNP according to some embodiments.
- parts 500a-500g include voids, or void spaces, S05, while parts 500h-500n are solid.
- parts 500a-500g may be printed using a polyvinyl alcohol (PVA) support.
- PVA polyvinyl alcohol
- parts 500a-500g may have void sizes of approximately 0.2mm to approximately 1.4mm.
- parts 500h-500n may have a thickness of approximately 0.2mm to approximately 2.0mm.
- the parts 500 are printed using nozzle and build plate temperatures of approximately 215°C and approximately 60°C, respectively. Additionally, in some embodiments, the parts 500 are printed using approximately 100% material infill. Furthermore, in some embodiments, the parts 500 are printed using approximately 0.1mm layer height. In some embodiments, the parts 500 are printed using a print speed of approximately 70mm/s.
- Fig. 6 is a flowchart illustrating a process, or operation, 600 for monitoring a material state of parts 500 according to some embodiments. It should be understood that the order of the steps disclosed in process 600 could vary. Additional steps may also be added to the control sequence and not all of the steps may be required.
- monitoring the material state of the parts 500 may include detecting defects in the parts 500. In such an embodiment, the defects may include missing print layers. In other embodiments, monitoring the material state of the parts 500 may include monitoring stress placed on the parts 500 by external loads and stimuli.
- Optical properties are monitored at a predetermined wavelength (block 605).
- the predetermined wavelength is approximately 300nm to approximately 800nm.
- a defect is determined based on the optical properties (block 610).
- the optical properties have a linear relationship with film thickness, or total number of print layers, of parts 500.
- the optical properties are monitored and the defects are detected, using a control system or controller.
- the controller includes a plurality of electrical and electronic components.
- the controller may include, among other things, an electronic processor (for example, a microprocessor or another suitable programmable device) and a memory.
- the memory includes, for example, a program storage area and a data storage area.
- the program storage area and the data storage area can include combinations of different types of memory, such as read-only memory (ROM), random access memory (RAM).
- ROM read-only memory
- RAM random access memory
- Various non-transitory computer readable media for example, magnetic, optical, physical, or electronic memory may be used.
- the electronic processor is communicatively coupled to the memory and executes software instructions that are stored in the memory, or stored on another non-transitory computer readable medium such as another memory or a disc.
- the software may include one or more applications, program data, filters, rules, one or more program modules, and other executable instructions.
- the software may include software for performing one or more steps of operation 600.
- the controller is electrically and/or communicatively coupled to a spectrophotometer, or similar wavelength measurement tool.
- Fig. 7 is a chart 700 illustrating an absorbance spectra of AuNP in solution and solid 3D printed parts using PLA/AuNP (for example, parts 50Oh-5OOn) having increasing thickness.
- Fig. 8 is a chart 800 illustrating a linear fit of the optical properties versus PLA/AuNP solid film thickness.
- the linear fit was calculated at a predetermined wavelength of approximately SI 3nm. In other embodiments, the fit may be calculated a different predetermined wavelength.
- Fig. 9 is a chart 900 illustrating an absorbance spectra of AuNP in solution and 3D printed parts using PLA/AuNP (for example, parts 500a-500g) having increasing void size.
- Fig. 10 is a chart 1000 illustrating a linear fit of the optical properties versus PLA/AuNP having increasing void size.
- the linear fit was calculated at a predetermined wavelength of approximately 513nm. In other embodiments, the fit may be calculated at a different predetermined wavelength.
- Fig. 11 is a chart 1100 illustrating the comparison of the linear fit of the optical properties versus PLA/AuNP solid film thickness and the linear fit of the optical properties versus PLA/AuNP having increasing void size.
- the optical properties have a linear relationship with film thickness, or total number of print layers. The linear relationship may be used to detect, and quantify, the presence of one or more void spaces and/or one or more defects in a 3D printed part.
- Fig. 12 is a flowchart illustrating a process, or operation, 1200 for detecting a defect in a 3D printed part according to some embodiments. It should be understood that the order of the steps disclosed in process 1200 could vary. Additional steps may also be added to the control sequence and not all of the steps may be required.
- Nanoparticles are incorporated into a polymer host matrix (block 1205).
- the nanoparticles are gold nanoparticles, however, in other embodiments, the nanoparticles may be silver, titanium dioxide, copper, cadmium selenide quantum dots, or a similar nanoparticle or quantum dot.
- the polymer host matrix is formed of polylatctic acid, however, in other embodiments, the polymer host matrix may be formed of acrylonitrile styrene (ABS), poly(methyl methacrylate) (PMMA), polycarbonate (PC), polyvinyl alcohol (PVA), polyvinylpyrrolidone (PVP), or a similar polymer.
- the polymer host matrix including the nanoparticles may then be used to manufacture a 3D part or structure.
- An optical response of the nanoparticles within the 3D part may then be analyzed (block 1210).
- the optical response is determined and/or analyzed via a spectrophotometer and/or a controller.
- a defect of the 3D part may be determined based on the optical response of the nanoparticles (block 1215).
- the application provides, among other things, a system and method for defect detection in a 3D printed structure. For example, by monitoring changes in optical properties (for example, absorbance intensity) in accordance with film thickness and void spacing, a relationship may be established to detect the presence of voids and/or missing print layer in a 3D printed structure.
- optical properties for example, absorbance intensity
- the system and method disclosed may detect, and quantify, defects in a 3D printed structure without the use of physical sensors.
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Abstract
A method of detecting defects in a three-dimensional printed part. The method includes incorporating nanoparticles within a polymer host matrix. The method further includes analyzing an optical response of the nanoparticles and determining a defect based on the optical response.
Description
SYSTEM AND METHOD FOR DETECTING DEFECTS IN THREE-DIMENSIONAL PRINTED PARTS
RELATED APPLICATIONS
[0001] This application claims the benefit to U.S. Provisional Patent Application No. 62/554,703, filed on September 6, 2017, the entire contents of which are incorporated herein by reference.
FIELD
[0002] Embodiments relate to three-dimensional printing.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0003] This invention was made with government support under N000141010958 awarded by the Office of Naval Research. The government has certain rights in mis invention.
SUMMARY
|0004] Three-dimensional (3D) printing, or additive manufacturing (AM), may refer to the process of creating a 3D structure under computer control. During 3D printing, defects may be formed in the final 3D printed structure.
[0005] Thus, one embodiment provides a method of detecting defects in a three- dimensional printed part. The method includes incorporating nanoparticles within a polymer host matrix. The method further includes analyzing an optical response of the nanoparticles and determining a defect based on the optical response.
[0006] Other aspects of the application will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Fig. 1 is a flowchart illustrating a process of three-dimensional printing according to some embodiments.
[0008] Fig. 2 is a flowchart illustrating a process for synthesizing nanoparticles according to some embodiments.
[0009] Fig. 3 is a chart illustrating an absorbance spectrum according to some embodiments.
[0010] Fig. 4 is a flowchart illustrating a process for fabricating filament according to some embodiments.
[0011] Fig. 5 is a top view of a plurality of three-dimensional printed parts according to some embodiments.
[0012] Fig. 6 is a flowchart illustrating a process for monitoring a material state of a three-dimensional printed part according to some embodiments.
[0013] Fig. 7 is a chart illustrating absorbance spectra according to some embodiments.
[0014] Fig. 8 is a chart illustrating a linear fit of optical properties according to some embodiments.
[0015] Fig. 9 is a chart illustrating absorbance spectra according to some embodiments.
[0016] Fig. 10 is a chart illustrating a linear fit of optical properties according to some embodiments.
[0017] Fig. 11 is a chart illustrating a comparison of the linear fits of Figs. 8 and 10 according to some embodiments.
|0018| Fig. 12 is a flowchart illustrating a process for determining a defect of a three- dimensional printed part according to some embodiments.
DETAILED DESCRIPTION
[0019] Before any embodiments of the application are explained in detail, it is to be understood that the application is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The application is capable of other embodiments and of being practiced or of being carried out in various ways.
[0020] This application discloses a material state diagnostic methodology for additively manufactured parts and materials based on the optical response of nanoparticles and quantum
dots. Embedded within a polymer host matrix (for example, polylactic acid (PLA), acrylonitrile styrene (ABS), poly(methyl methacrylate) (PMMA), polycarbonate (PC), polyvinyl alcohol (PVA), polyvinylpyrrolidone (PVP), etc.), the optical response of nanoparticles, or nanomaterials, (for example, gold, silver, titanium dioxide, copper, cadmium selenide quantum dots, etc.) may be used to develop an in-situ sensing
methodology to monitor the state and/or health of a material throughout its lifetime. Through various material processing steps, the methodology to incorporate nanoparticles and quantum dots within filament may be compatible with stock three-dimensional (3D) printers to print and manufacture materials capable of providing an indication of the material state in real time based on the unique optical response of the embedded nanoparticles alone.
[0021] In some embodiments, a number of missing print layers in 3D printed parts and materials may be detected through the inclusion of nanoparticles within a host matrix. By monitoring optical properties (for example, absorbance intensities) at a specific wavelength, the number of layers missing in 3D printed parts may be determined based on a relationship between optical properties and film thickness, or total number of print layers.
|0022| Embodiments disclosed may also be used to monitor a material state of 3D printed parts as the parts are exposed to external loads and stimuli in the intended applications of the 3D printed part(s). As such, not only can 3D printed materials be monitored for defects following printing (for quality control/validation and verification purposes), but also when the as printed parts are in service and exposed to external loads.
[0023] Fig. 1 is a flowchart illustrating a process, or operation, 100 of three-dimensional (3D) printing according to some embodiments. It should be understood that the order of the steps disclosed in process 100 could vary. Additional steps may also be added to the control sequence and not all of the steps may be required. Initially, a part (for example, parts 500a- 500n illustrated in Fig. S) is designed using computer aided design (CAD) software (block 105). The CAD design part is converted to an appropriate file for printing (block 110). The part is then printed using a material (for example, plastic, metal, polymer composite, etc.) (block 115).
[0024] In some embodiments, nanoparticles (for example, dodecanethiol stabilized gold nanoparticles (AuNPs)) may be incorporated into the part during printing. In other
embodiments, other nanoparticles (for example, silver nanoparticles, titanium dioxide nanoparticles, etc.) may be incorporated into the part during printing.
[0025] Fig. 2 is a flowchart illustrating a process, or operation, 200 for synthesizing nanoparticles according to some embodiments. It should be understood that the order of the steps disclosed in process 200 could vary. Additional steps may also be added to the control sequence and not all of the steps may be required. Furthermore, it should be noted that although process 200 describes synthesizing gold nanoparticles, process 200 may be used to synthesize nanoparticles formed of other materials.
[0026] Initially, a
precursor is prepared through a dropwise addition of triphenylphosphine (for example, approximately 3.6 mmol) to
(for example, approximately 1.8 mmol) in ethanol (for example, approximately S mL) (block 20S). In some embodiments, the mixture may be observed to change from a yellow color to white. The resulting solution may then be filtered and washed (block 210). In some embodiments, the solution is filtered and washed in ethanol and precipitated from acetone/THF (for example, 1 : 1 by volume). The resultant powder may then be recrystallized to obtain Au(PPh3)Cl (block 215). The gold nanoparticles may then be synthesized by dissolving Au(PPh3)Cl (for example, approximately 0.25 mmol) and approximately 125 uL of dodecanethiol in dry toluene (for example, approximately 20 mL) (block 220). The resulting mixture may be heated to a predetermined temperature (for example, approximately 50°C) (block 225). During heating, tert-butyl amine borane complex (for example, approximately 2.5 mmol) may be added to the mixture (block 230). After heating for a predetermined time (for example, approximately five minutes), the solution may change from clear to a purple color. In some embodiments, such a color change may indicate the formation of gold nanoparticles.
[0027] The gold nanoparticles may be precipitated in cold ethanol and centrifuged for a predetermined time (for example, approximately fifteen minutes) at a predetermined speed (for example, approximately 5 krpm) (block 235). The gold nanoparticles may then be washed one or more times (block 240). In some embodiments, the gold nanoparticles are washed with acetone via centrifugation for a predetermined time period (for example, approximately fifteen minutes) at a predetermined speed (for example, approximately 5 krpm). The resultant gold nanoparticles may then be redissolved in toluene (block 245).
[0028] Fig. 3 illustrates an absorbance spectrum 300 of gold nanoparticles suspended in toluene according to some embodiments. In the illustrated embodiment, the gold nanoparticles display a single, monotonic absorbance having a maximum peak occurring at approximately 513 nm. In some embodiments, the gold particles have a diameter of approximately 7.3 nm.
[0029] Fig. 4 is a flowchart illustrating a process, or operation, 400 for fabricating filament according to some embodiments. It should be understood that the order of the steps disclosed in process 400 could vary. Additional steps may also be added to the control sequence and not all of the steps may be required. A key consideration for functionalized filament fabrication includes an evaluation of miscibility between the selected polymer- nanoparticle system (405 and 410). In order to assess miscibility, Hildebrand solubility parameters may be used to provide an indication of how likely a solute and solvent are to mix and combine and offers a useful approximation for measuring polymer-nanoparticle interactions. When a solute and solvent, or polymer-nanoparticle mixture, have similar Hildebrand solubility parameters, they may be more likely to be miscible. In one embodiment, polylatctic acid (PL A) pellets are dissolved in dichloromethane (DCM) (block 405). In other embodiments, the PLA pellets may be dissolved in other solvents, for example, but not limited to Toluene, Acetone, Ethanol, Methanol, Chloroform, Benzene, and Tetrahydrofuran (THF). The gold nanoparticles suspended in toluene are then added to the dissolved PLA pellets (block 410). In some embodiments, the gold nanoparticles suspended in toluene may be added to the dissolved PLA pellets at a desired weight percent (for example, approximately 0.1% w/w AuNP/PLA). The PLA/AuNP mixtures may men be dried (block 415). In some embodiments, drying of the PLA/AuNP mixture may remove excess DCM. In some embodiments, drying of the PLA/AuNP mixture includes drying at a predetermined temperature (for example, approximately 20°C to approximately 25°C, approximately 100°C, and/or a combination of approximately 20°C to approximately 25°C and approximately 100°C). The PLA/AuNP mixture may then be extruded and spooled (block 420). In some embodiments, the PLA/AuNP mixture is extruded at a predetermined temperature (for example, approximately 170°C). In some embodiments, the PLA/AuNP mixture may be extruded at a predetermined diameter (for example, approximately 2mm to approximately 3mm, or approximately 2.7mm).
[0030] Fig. 5 is a top view of a plurality of parts, or structures, 500 printed using PLA/AuNP according to some embodiments. In the illustrated embodiment, parts 500a-500g include voids, or void spaces, S05, while parts 500h-500n are solid. In some embodiments, parts 500a-500g may be printed using a polyvinyl alcohol (PVA) support. In such an embodiment, the PVA may be dissolved and then removed using a water bath. In other embodiments, other polymers may be used as a support depending on the application. In some embodiments, parts 500a-500g may have void sizes of approximately 0.2mm to approximately 1.4mm. In some embodiments, parts 500h-500n may have a thickness of approximately 0.2mm to approximately 2.0mm.
[0031] In some embodiments, the parts 500 are printed using nozzle and build plate temperatures of approximately 215°C and approximately 60°C, respectively. Additionally, in some embodiments, the parts 500 are printed using approximately 100% material infill. Furthermore, in some embodiments, the parts 500 are printed using approximately 0.1mm layer height. In some embodiments, the parts 500 are printed using a print speed of approximately 70mm/s.
[0032| Fig. 6 is a flowchart illustrating a process, or operation, 600 for monitoring a material state of parts 500 according to some embodiments. It should be understood that the order of the steps disclosed in process 600 could vary. Additional steps may also be added to the control sequence and not all of the steps may be required. In some embodiments, monitoring the material state of the parts 500 may include detecting defects in the parts 500. In such an embodiment, the defects may include missing print layers. In other embodiments, monitoring the material state of the parts 500 may include monitoring stress placed on the parts 500 by external loads and stimuli.
[0033] Optical properties (for example, absorbance intensities) are monitored at a predetermined wavelength (block 605). In some embodiments, the predetermined wavelength is approximately 300nm to approximately 800nm. A defect is determined based on the optical properties (block 610). In some embodiments, the optical properties have a linear relationship with film thickness, or total number of print layers, of parts 500.
[0034] In some embodiments, the optical properties are monitored and the defects are detected, using a control system or controller. In some embodiments, the controller includes a plurality of electrical and electronic components. For example, the controller may include,
among other things, an electronic processor (for example, a microprocessor or another suitable programmable device) and a memory.
[0035| The memory includes, for example, a program storage area and a data storage area. The program storage area and the data storage area can include combinations of different types of memory, such as read-only memory (ROM), random access memory (RAM). Various non-transitory computer readable media, for example, magnetic, optical, physical, or electronic memory may be used. The electronic processor is communicatively coupled to the memory and executes software instructions that are stored in the memory, or stored on another non-transitory computer readable medium such as another memory or a disc. The software may include one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. For example, the software may include software for performing one or more steps of operation 600. In some embodiments, the controller is electrically and/or communicatively coupled to a spectrophotometer, or similar wavelength measurement tool.
[0036] Fig. 7 is a chart 700 illustrating an absorbance spectra of AuNP in solution and solid 3D printed parts using PLA/AuNP (for example, parts 50Oh-5OOn) having increasing thickness. Fig. 8 is a chart 800 illustrating a linear fit of the optical properties versus PLA/AuNP solid film thickness. In some embodiments, the linear fit was calculated at a predetermined wavelength of approximately SI 3nm. In other embodiments, the fit may be calculated a different predetermined wavelength.
[0037] Fig. 9 is a chart 900 illustrating an absorbance spectra of AuNP in solution and 3D printed parts using PLA/AuNP (for example, parts 500a-500g) having increasing void size. Fig. 10 is a chart 1000 illustrating a linear fit of the optical properties versus PLA/AuNP having increasing void size. In some embodiments, the linear fit was calculated at a predetermined wavelength of approximately 513nm. In other embodiments, the fit may be calculated at a different predetermined wavelength.
[0038] Fig. 11 is a chart 1100 illustrating the comparison of the linear fit of the optical properties versus PLA/AuNP solid film thickness and the linear fit of the optical properties versus PLA/AuNP having increasing void size. As illustrated, the optical properties have a linear relationship with film thickness, or total number of print layers. The linear relationship
may be used to detect, and quantify, the presence of one or more void spaces and/or one or more defects in a 3D printed part.
[0039| Fig. 12 is a flowchart illustrating a process, or operation, 1200 for detecting a defect in a 3D printed part according to some embodiments. It should be understood that the order of the steps disclosed in process 1200 could vary. Additional steps may also be added to the control sequence and not all of the steps may be required.
[0040] Nanoparticles are incorporated into a polymer host matrix (block 1205). As discussed above, in some embodiments, the nanoparticles are gold nanoparticles, however, in other embodiments, the nanoparticles may be silver, titanium dioxide, copper, cadmium selenide quantum dots, or a similar nanoparticle or quantum dot. Furthermore, as discussed above, in some embodiments, the polymer host matrix is formed of polylatctic acid, however, in other embodiments, the polymer host matrix may be formed of acrylonitrile styrene (ABS), poly(methyl methacrylate) (PMMA), polycarbonate (PC), polyvinyl alcohol (PVA), polyvinylpyrrolidone (PVP), or a similar polymer.
[0041] The polymer host matrix including the nanoparticles may then be used to manufacture a 3D part or structure. An optical response of the nanoparticles within the 3D part may then be analyzed (block 1210). In some embodiments, the optical response is determined and/or analyzed via a spectrophotometer and/or a controller. A defect of the 3D part may be determined based on the optical response of the nanoparticles (block 1215).
[0042] Thus, the application provides, among other things, a system and method for defect detection in a 3D printed structure. For example, by monitoring changes in optical properties (for example, absorbance intensity) in accordance with film thickness and void spacing, a relationship may be established to detect the presence of voids and/or missing print layer in a 3D printed structure. The system and method disclosed may detect, and quantify, defects in a 3D printed structure without the use of physical sensors. Various features and advantages of the application are set forth in the following claims.
Claims
1. A method of detecting defects in a three-dimensional printed part, the method comprising:
incorporating nanoparticles within a polymer host matrix;
analyzing an optical response of the nanoparticles; and
determining a defect based on the optical response.
2. The method of claim 1 , wherein the nanoparticles are formed from at least one selected from the group consisting of gold, silver, titanium dioxide, copper, and cadmium selenide quantum dots.
3. The method of claim 1 , wherein polymer host matrix is formed from at least one selected from the group consisting of acrylonitrile styrene (ABS), poly(methyl methacrylate) (PMMA), polycarbonate (PC), polyvinyl alcohol (PVA), and polyvinylpyrrolidone (PVP).
4. The method of claim 1 , wherein the polymer host matrix is selected according to Hildebrand solubility parameter estimations.
5. The method of claim 1 , wherein the step of incorporating nanoparticles with the polymer host matrix includes:
dissolving one or more pellets of the polymer host matrix; and
adding nanoparticles to the dissolved one or more pellets.
6. The method of claim 5, wherein the one or more pellets are dissolved in at least one selected from a group consisting of dichloromethane (DCM), Toluene, Acetone, Ethanol, Methanol, Chloroform, Benzene, and Tetrahydrofuran (THF).
7. The method of claim S, further including drying the composite polymer/nanoparticle mixture.
8. The method of claim 1 , wherein the step of analyzing the optical response of the nanoparticles includes monitoring an optical property.
9. The method of claim 1 , wherein the optical response of the nanoparticles is analyzed via at least one selected from the group consisting of a spectrophotometer, a computer vision system, a grayscale conversion system, an optical probe, and a fluorimeter.
10. The method of claim 1 , wherein the defect includes a missing print layer of the three- dimensional printed part
11. The method of claim 1 , wherein the step of determining the defect based on the optical response includes exposing the three-dimensional printed part to an external load.
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