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US20220088883A1 - Controlling heat sources based on representative temperatures - Google Patents

Controlling heat sources based on representative temperatures Download PDF

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Publication number
US20220088883A1
US20220088883A1 US17/543,458 US202117543458A US2022088883A1 US 20220088883 A1 US20220088883 A1 US 20220088883A1 US 202117543458 A US202117543458 A US 202117543458A US 2022088883 A1 US2022088883 A1 US 2022088883A1
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Prior art keywords
temperature
layer
regions
build material
additive manufacturing
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Abandoned
Application number
US17/543,458
Inventor
Ismael Fernandez Aymerich
Lluis Abello Rosello
Sergio PUIGARDEU ARAMENDIA
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Hewlett Packard Development Co LP
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Hewlett Packard Development Co LP
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Priority to US17/543,458 priority Critical patent/US20220088883A1/en
Assigned to HEWLETT-PACKARD DEVELOPMENT COMPANY, L.P. reassignment HEWLETT-PACKARD DEVELOPMENT COMPANY, L.P. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HP PRINTING AND COMPUTING SOLUTIONS, S.L.U.
Publication of US20220088883A1 publication Critical patent/US20220088883A1/en
Abandoned legal-status Critical Current

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/30Auxiliary operations or equipment
    • B29C64/386Data acquisition or data processing for additive manufacturing
    • B29C64/393Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20Direct sintering or melting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30Process control
    • B22F10/36Process control of energy beam parameters
    • B22F10/368Temperature or temperature gradient, e.g. temperature of the melt pool
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80Data acquisition or data processing
    • B22F10/85Data acquisition or data processing for controlling or regulating additive manufacturing processes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/90Means for process control, e.g. cameras or sensors
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00Producing shaped prefabricated articles from the material
    • B28B1/001Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B17/00Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
    • B28B17/0063Control arrangements
    • B28B17/0081Process control
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/10Processes of additive manufacturing
    • B29C64/141Processes of additive manufacturing using only solid materials
    • B29C64/153Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/10Processes of additive manufacturing
    • B29C64/165Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/10Processes of additive manufacturing
    • B29C64/188Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/20Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/295Heating elements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE 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
    • B33Y10/00Processes of additive manufacturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE 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
    • B33Y30/00Apparatus for additive manufacturing; Details thereof or accessories therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE 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
    • B33Y40/00Auxiliary operations or equipment, e.g. for material handling
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE 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
    • B33Y50/00Data acquisition or data processing for additive manufacturing
    • B33Y50/02Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05DSYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
    • G05D23/00Control of temperature
    • G05D23/19Control of temperature characterised by the use of electric means
    • G05D23/1917Control of temperature characterised by the use of electric means using digital means
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05DSYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
    • G05D23/00Control of temperature
    • G05D23/19Control of temperature characterised by the use of electric means
    • G05D23/1927Control of temperature characterised by the use of electric means using a plurality of sensors
    • G05D23/193Control of temperature characterised by the use of electric means using a plurality of sensors sensing the temperaure in different places in thermal relationship with one or more spaces
    • G05D23/1931Control of temperature characterised by the use of electric means using a plurality of sensors sensing the temperaure in different places in thermal relationship with one or more spaces to control the temperature of one space
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05DSYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
    • G05D23/00Control of temperature
    • G05D23/19Control of temperature characterised by the use of electric means
    • G05D23/27Control of temperature characterised by the use of electric means with sensing element responsive to radiation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20Direct sintering or melting
    • B22F10/28Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30Process control
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/10Auxiliary heating means
    • B22F12/17Auxiliary heating means to heat the build chamber or platform
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40Radiation means
    • B22F12/41Radiation means characterised by the type, e.g. laser or electron beam
    • B22F12/43Radiation means characterised by the type, e.g. laser or electron beam pulsed; frequency modulated
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00Aspects linked to processes or compositions used in powder metallurgy
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/25Process efficiency

Definitions

  • Additive manufacturing techniques may generate a three-dimensional object through the solidification of a build material, for example on a layer-by-layer basis.
  • build material may be supplied in a layer-wise manner and the solidification method may include heating the layers of build material to cause melting in selected regions.
  • chemical solidification and/or binding methods may be used.
  • FIG. 1 is an example method of controlling a heat source in additive manufacturing
  • FIG. 2A-2F are examples of pixels in heat maps
  • FIG. 3 is an example of a method of determining an average value
  • FIG. 4 is an example of a method for determining a representative temperature in additive manufacturing
  • FIG. 5 is an example of a heat map
  • FIG. 6 is an example of a chart for determining a representative temperature in additive manufacturing
  • FIG. 7 is an example of an additive manufacturing apparatus
  • FIG. 8 is another example of an additive manufacturing apparatus.
  • FIG. 9 is an example machine readable medium associated with a processor.
  • Additive manufacturing techniques may generate a three-dimensional object through the solidification of a build material.
  • the build material is a powder-like granular material, which may for example be a plastic, ceramic or metal powder and the properties of generated objects may depend on the type of build material and the type of solidification mechanism used.
  • Build material may be deposited, for example on a print bed and processed layer by layer, for example within a fabrication chamber.
  • selective solidification is achieved through directional application of energy, for example using a laser or electron beam which results in solidification of build material where the directional energy is applied.
  • at least one print agent may be selectively applied to the build material, and may be liquid when applied.
  • Build material may be deposited, for example, on a print bed, and processed layer by layer, for example within a fabrication chamber or “build volume” of the printer.
  • the build material may be a powder-like granular material, which may for example be a plastic, ceramic or metal powder.
  • a suitable build material may be PA12 build material commercially known as V1R10A “HP PA12” available from HP Inc.
  • At least one print agent may be selectively applied to the build material, and may be liquid when applied.
  • a fusing agent also termed a “coalescence agent” or “coalescing agent”
  • the fusing agent may have a composition which absorbs energy such that, when energy (for example, heat) is applied to the layer, the build material coalesces and solidifies to form a slice of the three-dimensional object in accordance with the pattern.
  • a suitable fusing agent may be an ink-type formulation comprising carbon black, such as, for example, the fusing agent formulation commercially known as V1Q60Q “HP fusing agent” available from HP Inc.
  • a fusing agent may additionally comprise an infra-red light absorber.
  • a fusing agent may additionally comprise a near infra-red light absorber.
  • a fusing agent may additionally comprise a visible light absorber.
  • such a fusing agent may additionally comprise a UV light absorber.
  • print agents comprising visible light enhancers are dye based colored ink and pigment based colored ink, such as inks commercially known as CE039A and CE042A available from HP Inc.
  • coalescence may be achieved in some other manner.
  • a detailing agent may also be used (also termed a “coalescence modifier agent” or “coalescing modifier agent”), which may have a cooling effect.
  • the detailing agent may be used near edge surfaces of an object being printed.
  • a suitable detailing agent may be a formulation commercially known as V1Q61A “HP detailing agent” available from HP Inc.
  • a coloring agent for example comprising a dye or colorant, may in some examples be used as a fusing agent or a coalescence modifier agent, and/or as a print agent to provide a particular color for the object.
  • Print agents may control or influence other physical or appearance properties, such as strength, resilience, conductivity, transparency, surface texture or the like.
  • heat sources for example, infrared emitters such as a heat lamp, which may comprise statically mounted heat sources directed at a print bed
  • a feedback loop is used, and one or more heat sources are controlled according to a measured temperature.
  • a layer of build material is divided into a plurality of print bed zones, each associated with a heat source. An average or representative temperature of the build material in each zone may be determined, and the heat source in turn controlled according to that temperature.
  • the reference temperature to be used for a feedback loop is intended to be the temperature of build material in the absence of print agent, which will be referred to herein as ‘blank’ build material.
  • portions of a layer of build material may be treated with a print agent, for example any of the print agents described above.
  • a print agent for example any of the print agents described above.
  • fusing agent will tend to increase the temperature in a region and, in particular where the resolution with which the temperature is within that region can be measured is relatively low, this can make it difficult to correctly determine the temperature of blank build material, as some temperature measurements may include both treated and blank build material, or heat may be transferred between treated and blank build material, and this in turn can result in incorrect or sub-optimal control of the heat sources.
  • FIG. 1 is an example of a method of additive manufacturing, which may be a layer by layer object generation process, otherwise known as 3D printing.
  • the temperature of each of a plurality of regions of a layer of build material in an additive manufacturing apparatus is measured to provide initial temperature values.
  • a ‘heat map’ of the layer of build material may be acquired, for example using one or more thermal cameras.
  • the heat map may be made up of an array of pixels, each corresponding to a region of the layer of build material, and the temperature of each of such pixels/regions may be monitored.
  • the array may be on the order of 22-40 pixels square, in some examples being 32 pixels square.
  • Block 104 comprises determining, for each of a plurality of regions which comprise build material which is intended to fuse, an average temperature value of a plurality of neighbouring regions and block 106 comprises replacing the initial temperature values with the average temperature values.
  • a pixel which comprises a thermal image of a region of the build material which includes at least some build material which is intended to fuse, or which is closer there to may have an initial temperature value.
  • This temperature value may, in general, be higher than a temperature value of blank or untreated build material.
  • Such values are replaced by an average temperature value determined by averaging neighbouring regions.
  • the neighbouring regions may comprise regions in which the initial measured temperature is a temperature associated with blank build material and/or previously replaced initial temperature values.
  • the initial values of a plurality of regions which comprise build material which is intended to fuse may first be replaced by a null value before being replaced with an average temperature value.
  • the regions which comprise build material which is intended to fuse are determined, at least in part, by reference to control data used to instruct the distribution of print agents.
  • control data may be generated based on object model data representing at least a portion of an object to be generated by an additive manufacturing apparatus by fusing build material.
  • the object model data may for example comprise a Computer Aided Design (CAD) model, and/or may for example be a STereoLithographic (STL) data file.
  • CAD Computer Aided Design
  • STL STereoLithographic
  • these regions may be identified by temperature. For example regions in which pixels which are above a threshold temperature may be identified as relating to build material which is intended to fuse.
  • Block 108 comprises determining, based on the replacement temperature values, a representative temperature of an area of the layer of build material. For example, this may comprise selecting an area of the layer of build material corresponding to a particular heat source (a ‘print bed zone’).
  • An average temperature which may include an average of initial temperatures and/or of at least some replacement temperatures determined in blocks 104 and 106 may be determined as a representative temperature for this area. In other examples, the area may comprise the print bed as a whole.
  • Block 110 comprises controlling a heat source based on the representative temperature. This may for example comprise controlling a power level of a heat source heating the layer of build material. Controlling the power level may comprise controlling the average power level over time, for example using pulse width modulation control, which sets the percentage of time for which a heating element is emitting light. In other examples, the power level of a constant heat output may be controlled.
  • the heat sources may be, for example heat lamps, such as infrared heat lamps.
  • Controlling the heat source in block 110 may be carried out as a ‘closed-loop’ control process.
  • a temperature which is more representative of the blank build material temperature may be determined.
  • the method of FIG. 1 results in improved accuracy.
  • FIG. 2A shows an example of a heat map 200 of a layer of build material during object generation in which centigrade temperature measurements are given as whole numbers (although in practice, temperatures may be recorded to a higher level of accuracy).
  • a portion 202 of the layer which comprises a plurality of pixels/regions of the build material which is intended to fuse
  • solidification of the build material is taking place and the temperature of the pixels therein is generally higher.
  • the temperature values are generally lower. This is because heat is lost to the environment surrounding the fabrication chamber. It may be noted that the edge region is larger in the corners (or tapers with distance from the corner).
  • the pixels at the corners correspond to a different size of region of the build material than those at the centre. This may not be the case in all examples, for example if an array of temperature sensors which was of a similar size to the print bed was used and therefore such regions may not be present or may differ in appearance in other examples.
  • FIG. 2B shows a version of this in which the data relating to the portion 202 which is intended to fuse and the edge regions 204 has been removed.
  • this data may be replaced with a null value of 0 (zero).
  • the remaining temperature values are indicative of the temperature of the blank build material in the layer.
  • FIGS. 2C and 2D show the result of replacing values with an average value in a first replacement operation.
  • an average value for a pixel 206 may be determined from four neighbouring pixels 208 a - d (which in this example are shown to two decimal places), where neighbouring pixels 208 are selected from a first and second side of the pixel 206 to be overwritten.
  • the data is replaced in a ‘sweep’ which starts from the top left-hand of the heat map and extends through to the bottom right of the heat map.
  • the sweep starts with the first null pixel 206 which has a set of non-null neighbour pixels 208 .
  • neighbour pixels 208 While four neighbour pixels 208 have been used for determining the average in this example, more or fewer pixels may be used in other examples.
  • neighbour pixels are direct neighbours in this example (i.e. they adjoin the pixel whose value is to be replaced), in other examples, the neighbour pixels may be from the vicinity of the pixel whose value is to be replaced, but not directed adjoining that pixel.
  • selecting neighbouring pixels which are to the left and above the pixel to be overwritten sweeps data through the heat map 200 .
  • there may be a second sweep through the data for example starting from the bottom right-hand corner and ending in the top left-hand corner.
  • an average may be based on pixels which are to the right and below the pixel to be overwritten, as is shown in FIG. 2E (in which T ave is the average of T 1 , T 2 , T 3 and T 4 ), and FIG. 2F . This may propagate values into the top and/or left-hand corners.
  • all pixels which are shown as null value or ‘0’ pixels in FIG. 2B are replaced (meaning that some null pixels may be overwritten twice: first with an initial replacement average value and then with a second replacement average value).
  • FIG. 2F shows an example of a heat map with the temperature values of a portion 202 which comprises build material which is intended to fuse and the temperature values of regions 204 which are in a boundary zone of the layer have been replaced with an average temperature based on neighbouring regions.
  • FIG. 3 is an example of a method for carrying out blocks 104 and 106 of FIG. 1 .
  • Block 302 comprises, determining, for a plurality of regions, a first replacement temperature value comprising a weighted average value of neighbouring regions on a first and second side of each region. For example, this may comprise the left and top side of the pixel, as described above in relation to FIGS. 2C and 2D . Therefore, this may comprise carrying out a first sweep e.g. top left to bottom right as described above.
  • Block 304 comprises determining, for a plurality of regions, a second replacement temperature value comprising a weighted average value of neighbouring regions on a third and fourth side region. This may for example comprise the right and under side of the pixel, as described above in relation to FIGS. 2E and 2F . In some examples, this may comprise carrying out a second sweep, e.g. bottom right top left as described above. More generally, the first and second sides may be adjoining orthogonal sides, and the third and fourth sides may be adjoining orthogonal sides.
  • the temperature values of pixels/regions which are not initially representative of the temperature of blank build material may be replaced, whereas the temperature values of pixels/regions which are representative of the temperature of blank build material may remain as initially measured.
  • additional smoothing may be carried out, and/or a first replacement average value may not be overwritten by a second replacement average value.
  • the average values are weighted values.
  • the weighting may be indicative of whether the temperature value of the neighbouring region is an initial value or a replacement value.
  • the weighting may indicate the number of initial values which we used to determine the replacement value. Thus, for the sake of example, if a value contributing to the average is an initial value, this may have a weighting of 5. If the value is a replacement value which was determined using three initial values and one replacement value, this may have a weighting of 4. If the value is a replacement value which was determined using two initial values and two replacement values, it may have a weighting of 3. If the value is a replacement value which was determined using one initial value and three replacement values, it may have a weighting of 2. If the value is a replacement value which was determined using four replacement values, it may have a weighting of 1.
  • a more complete history of the weight of initial values remaining in a replacement value may be used to determine its weighting in an average.
  • This method may be carried out for regions of the build material which are intended to fuse and/or for at least one region which are within the boundary zone of the layer.
  • a representative temperature of an area of the layer of build material may be determined based on the replacement temperature values of the regions which correspond to portions of the layer which are intended to fuse and those which are in the boundary zone.
  • FIG. 4 is another example of a method of additive manufacturing comprising, in block 402 , measuring the temperature of a plurality of regions of the layer of build material in an additive manufacturing apparatus to provide initial temperature values. The operation may be carried out as described above in relation to block 102 .
  • Block 404 comprises determining the size of a continuous area of the layer of build material which comprises build material which is intended to fuse. This may be determined based on control data, object model data, or thermal data such as measured temperature, as described above in relation to block 404 . In some examples, there may be several regions which are intended to fuse and each of these regions may be considered individually.
  • Block 406 comprises comparing the size to a threshold size. In the event that the size is below the threshold size, the method proceeds with block 104 of FIG. 1 . However, in the event that the size is above the threshold size, the method continues with block 408 which comprises using a linear regression and a predicted heat of each region based on data indicating the portions of the layer which are intended to fuse to estimate the representative temperature.
  • the method of FIG. 1 may be used for continuous regions up to a threshold size and the method of block 408 may be used for regions above this size.
  • the threshold size may be determined for each of a plurality of print bed zones, the zones being associated with different heat sources.
  • FIG. 5 shows an example of a heat map of a zone of a layer of build material associated with a particular heat source in which a large proportion (the white portion) is intended to fuse.
  • the zone may be one of, for example twelve zones of the layer.
  • a predicted heat of each region may be determined based on an amount of print agent to be applied thereto and, in some examples, the predicted temperature of surrounding regions.
  • any optical distortion for example due to fisheye lens(es) applied to the thermal camera, as is shown in FIG. 5 , or the like, may be taken into account.
  • untreated powder may be associated with a grey level value of 0.
  • detailing agent may be used to cool powder. Therefore, in some examples, the grey level associated with such detailing agents may for example be in the region of 0 to 20, the white powder may be associated with a grey level of around 20 to 25 (in some examples 23) and pixels associated with the application of fusing agent may be associated with higher grey level values.
  • the grey levels for each pixel may then be plotted against the measured temperature value for that pixel. In some examples, an average of the measured temperatures for all pixels with a particular assigned grey level may be determined.
  • the average measured temperature of the pixels with a grey level of 0 is 154.50° C.
  • the average measured temperature value of the pixels with a grey level of 9 is 156.00° C.
  • the average measured temperature of the pixels with a grey level of 28 is 155.50° C.
  • the measured temperature of the pixel with a grey level of 61 is 156.00° C. and the measured temperature of the pixel with a grey level of 102 is 157.00° C.
  • FIG. 6 shows a plot of these grey levels against the averages of the measured temperatures.
  • the zero crossing point of a ‘best fit’ line provides the representative temperature in this example. Therefore, this method uses linear regression to determine the representative temperature.
  • the linear regression may be carried out for a plurality of zones, each zone being associated with a different heat source. In one example, a linear regression may be carried out for each of a plurality of zones separately.
  • FIG. 7 is an example of an additive manufacturing apparatus 700 comprising processing circuitry 702 , the processing circuitry 702 comprises a temperature determination module 704 and a controller 706 .
  • the temperature determination module 704 is, in use of the apparatus, to determine a representative temperature of the layer of build material by replacing measured temperature values of a pixel of a heat map of the layer which comprises build material which is intended to fuse with average temperatures of neighbouring pixels. For example, this may comprise carrying out the methods of FIG. 1 and FIG. 2 described above.
  • the controller 706 is to control at least one heat source based on the representative temperature value of the layer of build material.
  • FIG. 8 shows an example of an additive manufacturing apparatus 800 comprising the processing circuitry 702 including the temperature determination module 704 and the controller 706 of FIG. 7 .
  • the additive manufacturing apparatus 800 comprises a plurality of heat sources 802 a - d and a print bed 804 (although it will be understood that the print bed 804 and/or the heat sources 802 a - d may be supplied separately from other additive manufacturing apparatus components).
  • the heat sources 802 are arranged in an array, each heat source 802 being associated with a zone of the print bed 804 .
  • the temperature determination module 704 is to determine a plurality of representative temperature is a different zones of a layer of build material and the controller 706 is to control a plurality of heat sources based on the representative temperature value for an associated zone.
  • the additive manufacturing apparatus 700 , 800 may comprise or otherwise be provided with or operate in association with temperature sensing apparatus.
  • temperature sensing apparatus may for example comprise a thermal imaging camera to obtain a thermal image/heat map of the print bed, wherein the thermal image/heat map comprises a plurality of pixels, each pixel having an associated measured temperature.
  • temperature sensing apparatus may comprise a thermal imaging sensor array, or some other thermal sensing apparatus, and may be used to determine one or more temperatures (which may be pixels of a heat map).
  • the additive manufacturing apparatus 700 , 800 may generate objects in a layer-wise manner by selectively solidifying portions of layers of build materials.
  • the selective solidification may in some examples be achieved by selectively applying print agents, for example through use of ‘inkjet’ liquid distribution technologies, and applying energy, for example heat, to each layer.
  • the additive manufacturing apparatus 700 , 800 may comprise additional components not shown herein, for example a fabrication chamber, at least one print head for distributing print agents, a build material distribution system for providing layers of build material and the like.
  • the additive manufacturing apparatus 700 , 800 may, in some examples, carry out at least one of the blocks of FIG. 1, 3 or 4 .
  • FIG. 9 shows an example of a tangible machine readable medium 900 in association with a processor 902 .
  • the machine readable medium 900 stores instructions 904 which, when executed by the processor 902 cause the processor to carry out actions.
  • the instructions 904 comprise instructions 906 to identify, from a heat map of the layer of build material in an additive manufacturing apparatus comprising a plurality of pixels, the pixels which are directly indicative of a temperature of the layer in the absence of applied print agent, i.e. the blank pixels.
  • the instructions 904 further comprise instructions 908 to cause the processor 902 to determine, for a plurality of pixels which are not directly indicative of a temperature of the layer in the absence of applied print agent (e.g. treated and/or edge pixels), an average temperature value of a plurality of neighbouring regions.
  • the instructions 904 further comprise instructions 910 to cause the processor 902 to determine, based on the directly indicative pixels and the determined average temperature values, a representative temperature of an area of the layer of build material.
  • the instructions 904 further comprise instructions 912 to cause the processor 902 to control a heat source based on the representative temperature.
  • the instructions 906 may comprise instructions to determine the pixels based on data modelling the content of a fabrication chamber.
  • the blank pixels may be identified based on control data (for example specifying where print agents have been/are to be placed), and/or measured temperature values, for example based on threshold values.
  • the instructions 908 to determine an average temperature value comprise, for at least one pixel which is not directly indicative of a temperature of the layer in the absence of applied print agent, instructions to determine a first average temperature value of a first plurality of neighbouring regions, and a second average temperature value of a second plurality of neighbouring regions.
  • the instructions 904 may comprise instructions to cause the processor 902 to determine the size of a continuous set of pixels which are not directly indicative of a temperature of the layer in the absence of applied print agent, and when the area is below a threshold size, determining the average temperatures, and, when the area is at least a threshold size, using a linear regression and a predicted heat of each region to determine a representative temperature.
  • Examples in the present disclosure can be provided as methods, systems or machine readable instructions, such as any combination of software, hardware, firmware or the like.
  • Such machine readable instructions may be included on a computer readable storage medium (including but not limited to disc storage, CD-ROM, optical storage, etc.) having computer readable program codes therein or thereon.
  • the machine readable instructions may, for example, be executed by a general purpose computer, a special purpose computer, an embedded processor or processors of other programmable data processing devices to realize the functions described in the description and diagrams.
  • a processor or processing circuitry may execute the machine readable instructions.
  • functional modules of the apparatus such as the temperature determination module 704 and the controller 706
  • the term ‘processor’ is to be interpreted broadly to include a CPU, processing unit, ASIC, logic unit, or programmable gate array etc.
  • the methods and functional modules may all be performed by a single processor or divided amongst several processors.
  • Such machine readable instructions may also be stored in a computer readable storage that can guide the computer or other programmable data processing devices to operate in a specific mode.
  • Machine readable instructions may also be loaded onto a computer or other programmable data processing devices, so that the computer or other programmable data processing devices perform a series of operations to produce computer-implemented processing, thus the instructions executed on the computer or other programmable devices realize functions specified by flow(s) in the flow charts and/or block(s) in the block diagrams.
  • teachings herein may be implemented in the form of a computer software product, the computer software product being stored in a storage medium and comprising a plurality of instructions for making a computer device implement the methods recited in the examples of the present disclosure.

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Abstract

In an example, a method includes measuring a temperature of a plurality of regions of a layer of build material in an additive manufacturing apparatus to provide initial temperature values. For each of a plurality of regions which comprise build material which is intended to fuse, an average temperature value of a plurality of neighbouring regions may be determined and the initial temperature values may be replaced with the average temperature value. Based on the replacement temperature values, a representative temperature of an area of the layer of build material may be determined and a heat source may be controlled based on the representative temperature.

Description

    BACKGROUND
  • Additive manufacturing techniques may generate a three-dimensional object through the solidification of a build material, for example on a layer-by-layer basis. In examples of such techniques, build material may be supplied in a layer-wise manner and the solidification method may include heating the layers of build material to cause melting in selected regions. In other techniques, chemical solidification and/or binding methods may be used.
  • BRIEF DESCRIPTION OF DRAWINGS
  • Non-limiting examples will now be described with reference to the accompanying drawings, in which:
  • FIG. 1 is an example method of controlling a heat source in additive manufacturing;
  • FIG. 2A-2F are examples of pixels in heat maps;
  • FIG. 3 is an example of a method of determining an average value;
  • FIG. 4 is an example of a method for determining a representative temperature in additive manufacturing;
  • FIG. 5 is an example of a heat map;
  • FIG. 6 is an example of a chart for determining a representative temperature in additive manufacturing;
  • FIG. 7 is an example of an additive manufacturing apparatus;
  • FIG. 8 is another example of an additive manufacturing apparatus; and
  • FIG. 9 is an example machine readable medium associated with a processor.
  • DETAILED DESCRIPTION
  • Additive manufacturing techniques may generate a three-dimensional object through the solidification of a build material. In some examples, the build material is a powder-like granular material, which may for example be a plastic, ceramic or metal powder and the properties of generated objects may depend on the type of build material and the type of solidification mechanism used. Build material may be deposited, for example on a print bed and processed layer by layer, for example within a fabrication chamber.
  • In some examples, selective solidification is achieved through directional application of energy, for example using a laser or electron beam which results in solidification of build material where the directional energy is applied. In other examples, at least one print agent may be selectively applied to the build material, and may be liquid when applied.
  • Some 3D printing technology works by generating layers of a given thickness, one on top of another. Build material may be deposited, for example, on a print bed, and processed layer by layer, for example within a fabrication chamber or “build volume” of the printer. The build material may be a powder-like granular material, which may for example be a plastic, ceramic or metal powder. According to one example, a suitable build material may be PA12 build material commercially known as V1R10A “HP PA12” available from HP Inc.
  • In some examples, at least one print agent may be selectively applied to the build material, and may be liquid when applied. For example, a fusing agent (also termed a “coalescence agent” or “coalescing agent”) may be selectively distributed onto portions of a layer of build material in a pattern derived from data representing a slice of a three-dimensional object to be generated (which may for example be generated from structural design data). The fusing agent may have a composition which absorbs energy such that, when energy (for example, heat) is applied to the layer, the build material coalesces and solidifies to form a slice of the three-dimensional object in accordance with the pattern.
  • According to one example, a suitable fusing agent may be an ink-type formulation comprising carbon black, such as, for example, the fusing agent formulation commercially known as V1Q60Q “HP fusing agent” available from HP Inc. In some examples such a fusing agent may additionally comprise an infra-red light absorber. In some examples such a fusing agent may additionally comprise a near infra-red light absorber. In some examples such a fusing agent may additionally comprise a visible light absorber. In some examples such a fusing agent may additionally comprise a UV light absorber. Examples of print agents comprising visible light enhancers are dye based colored ink and pigment based colored ink, such as inks commercially known as CE039A and CE042A available from HP Inc.
  • In other examples, coalescence may be achieved in some other manner.
  • In some examples, a detailing agent may also be used (also termed a “coalescence modifier agent” or “coalescing modifier agent”), which may have a cooling effect. In some examples, the detailing agent may be used near edge surfaces of an object being printed. According to one example, a suitable detailing agent may be a formulation commercially known as V1Q61A “HP detailing agent” available from HP Inc.
  • A coloring agent, for example comprising a dye or colorant, may in some examples be used as a fusing agent or a coalescence modifier agent, and/or as a print agent to provide a particular color for the object. Print agents may control or influence other physical or appearance properties, such as strength, resilience, conductivity, transparency, surface texture or the like.
  • In some examples of additive manufacturing, heat sources (for example, infrared emitters such as a heat lamp, which may comprise statically mounted heat sources directed at a print bed) are controlled to maintain an appropriate temperature range during object generation. In some examples, a feedback loop is used, and one or more heat sources are controlled according to a measured temperature. In some examples, a layer of build material is divided into a plurality of print bed zones, each associated with a heat source. An average or representative temperature of the build material in each zone may be determined, and the heat source in turn controlled according to that temperature.
  • In some examples, the reference temperature to be used for a feedback loop is intended to be the temperature of build material in the absence of print agent, which will be referred to herein as ‘blank’ build material.
  • However, during an object generation process, portions of a layer of build material may be treated with a print agent, for example any of the print agents described above. For example, fusing agent will tend to increase the temperature in a region and, in particular where the resolution with which the temperature is within that region can be measured is relatively low, this can make it difficult to correctly determine the temperature of blank build material, as some temperature measurements may include both treated and blank build material, or heat may be transferred between treated and blank build material, and this in turn can result in incorrect or sub-optimal control of the heat sources.
  • FIG. 1 is an example of a method of additive manufacturing, which may be a layer by layer object generation process, otherwise known as 3D printing. In block 102, the temperature of each of a plurality of regions of a layer of build material in an additive manufacturing apparatus is measured to provide initial temperature values. In some examples, a ‘heat map’ of the layer of build material may be acquired, for example using one or more thermal cameras. The heat map may be made up of an array of pixels, each corresponding to a region of the layer of build material, and the temperature of each of such pixels/regions may be monitored. For example, the array may be on the order of 22-40 pixels square, in some examples being 32 pixels square.
  • Block 104 comprises determining, for each of a plurality of regions which comprise build material which is intended to fuse, an average temperature value of a plurality of neighbouring regions and block 106 comprises replacing the initial temperature values with the average temperature values. For example, a pixel which comprises a thermal image of a region of the build material which includes at least some build material which is intended to fuse, or which is closer there to, may have an initial temperature value. This temperature value may, in general, be higher than a temperature value of blank or untreated build material. In this example, such values are replaced by an average temperature value determined by averaging neighbouring regions. The neighbouring regions may comprise regions in which the initial measured temperature is a temperature associated with blank build material and/or previously replaced initial temperature values. In some examples, the initial values of a plurality of regions which comprise build material which is intended to fuse may first be replaced by a null value before being replaced with an average temperature value.
  • In some examples, the regions which comprise build material which is intended to fuse are determined, at least in part, by reference to control data used to instruct the distribution of print agents. Such control data may be generated based on object model data representing at least a portion of an object to be generated by an additive manufacturing apparatus by fusing build material. The object model data may for example comprise a Computer Aided Design (CAD) model, and/or may for example be a STereoLithographic (STL) data file.
  • In some examples, these regions may be identified by temperature. For example regions in which pixels which are above a threshold temperature may be identified as relating to build material which is intended to fuse.
  • Block 108 comprises determining, based on the replacement temperature values, a representative temperature of an area of the layer of build material. For example, this may comprise selecting an area of the layer of build material corresponding to a particular heat source (a ‘print bed zone’). An average temperature, which may include an average of initial temperatures and/or of at least some replacement temperatures determined in blocks 104 and 106 may be determined as a representative temperature for this area. In other examples, the area may comprise the print bed as a whole.
  • Block 110 comprises controlling a heat source based on the representative temperature. This may for example comprise controlling a power level of a heat source heating the layer of build material. Controlling the power level may comprise controlling the average power level over time, for example using pulse width modulation control, which sets the percentage of time for which a heating element is emitting light. In other examples, the power level of a constant heat output may be controlled.
  • In some examples, the heat sources may be, for example heat lamps, such as infrared heat lamps. In some examples, there may be an array of heat sources overlying a print bed in an additive manufacturing apparatus. In some examples, there may be on the order of 10, 20, or 50 heat sources. Controlling the heat source in block 110 may be carried out as a ‘closed-loop’ control process.
  • By replacing temperatures associated with regions of the build material which are intended to fuse (i.e. those which have fusing agent applied thereto) with average temperatures, a temperature which is more representative of the blank build material temperature may be determined. When compared to, for example, simply replacing a ‘hot’ pixel with a temperature value from a neighbouring pixel, the method of FIG. 1 results in improved accuracy.
  • FIG. 2A shows an example of a heat map 200 of a layer of build material during object generation in which centigrade temperature measurements are given as whole numbers (although in practice, temperatures may be recorded to a higher level of accuracy). In a portion 202 of the layer (which comprises a plurality of pixels/regions of the build material which is intended to fuse), solidification of the build material is taking place and the temperature of the pixels therein is generally higher. In addition, it may be noted that in the edge regions 204 a-d, the temperature values are generally lower. This is because heat is lost to the environment surrounding the fabrication chamber. It may be noted that the edge region is larger in the corners (or tapers with distance from the corner). This is, at least in part, an artefact of the thermal camera used to measure the temperatures in this example, which is used in association with a fisheye lens. Therefore, the pixels at the corners correspond to a different size of region of the build material than those at the centre. This may not be the case in all examples, for example if an array of temperature sensors which was of a similar size to the print bed was used and therefore such regions may not be present or may differ in appearance in other examples.
  • FIG. 2B, shows a version of this in which the data relating to the portion 202 which is intended to fuse and the edge regions 204 has been removed. In some examples, this data may be replaced with a null value of 0 (zero). The remaining temperature values are indicative of the temperature of the blank build material in the layer.
  • FIGS. 2C and 2D show the result of replacing values with an average value in a first replacement operation. As is shown in FIG. 2D, in this example an average value for a pixel 206 may be determined from four neighbouring pixels 208 a-d (which in this example are shown to two decimal places), where neighbouring pixels 208 are selected from a first and second side of the pixel 206 to be overwritten. In this example, the data is replaced in a ‘sweep’ which starts from the top left-hand of the heat map and extends through to the bottom right of the heat map. In this example, the sweep starts with the first null pixel 206 which has a set of non-null neighbour pixels 208. While four neighbour pixels 208 have been used for determining the average in this example, more or fewer pixels may be used in other examples. In addition, while the neighbour pixels are direct neighbours in this example (i.e. they adjoin the pixel whose value is to be replaced), in other examples, the neighbour pixels may be from the vicinity of the pixel whose value is to be replaced, but not directed adjoining that pixel.
  • Therefore, selecting neighbouring pixels which are to the left and above the pixel to be overwritten sweeps data through the heat map 200. In some examples, there may be a second sweep through the data, for example starting from the bottom right-hand corner and ending in the top left-hand corner. In the second sweep, an average may be based on pixels which are to the right and below the pixel to be overwritten, as is shown in FIG. 2E (in which Tave is the average of T1, T2, T3 and T4), and FIG. 2F. This may propagate values into the top and/or left-hand corners. In this example, all pixels which are shown as null value or ‘0’ pixels in FIG. 2B are replaced (meaning that some null pixels may be overwritten twice: first with an initial replacement average value and then with a second replacement average value).
  • Thus, FIG. 2F shows an example of a heat map with the temperature values of a portion 202 which comprises build material which is intended to fuse and the temperature values of regions 204 which are in a boundary zone of the layer have been replaced with an average temperature based on neighbouring regions.
  • FIG. 3 is an example of a method for carrying out blocks 104 and 106 of FIG. 1.
  • Block 302 comprises, determining, for a plurality of regions, a first replacement temperature value comprising a weighted average value of neighbouring regions on a first and second side of each region. For example, this may comprise the left and top side of the pixel, as described above in relation to FIGS. 2C and 2D. Therefore, this may comprise carrying out a first sweep e.g. top left to bottom right as described above. Block 304 comprises determining, for a plurality of regions, a second replacement temperature value comprising a weighted average value of neighbouring regions on a third and fourth side region. This may for example comprise the right and under side of the pixel, as described above in relation to FIGS. 2E and 2F. In some examples, this may comprise carrying out a second sweep, e.g. bottom right top left as described above. More generally, the first and second sides may be adjoining orthogonal sides, and the third and fourth sides may be adjoining orthogonal sides.
  • In this example, in both the first and second sweep, the temperature values of pixels/regions which are not initially representative of the temperature of blank build material may be replaced, whereas the temperature values of pixels/regions which are representative of the temperature of blank build material may remain as initially measured. However in other examples, additional smoothing may be carried out, and/or a first replacement average value may not be overwritten by a second replacement average value.
  • In the example of FIG. 3, the average values are weighted values. For example, the weighting may be indicative of whether the temperature value of the neighbouring region is an initial value or a replacement value. Further, in some examples, the weighting may indicate the number of initial values which we used to determine the replacement value. Thus, for the sake of example, if a value contributing to the average is an initial value, this may have a weighting of 5. If the value is a replacement value which was determined using three initial values and one replacement value, this may have a weighting of 4. If the value is a replacement value which was determined using two initial values and two replacement values, it may have a weighting of 3. If the value is a replacement value which was determined using one initial value and three replacement values, it may have a weighting of 2. If the value is a replacement value which was determined using four replacement values, it may have a weighting of 1.
  • In other examples a more complete history of the weight of initial values remaining in a replacement value may be used to determine its weighting in an average.
  • This method may be carried out for regions of the build material which are intended to fuse and/or for at least one region which are within the boundary zone of the layer. In such examples, a representative temperature of an area of the layer of build material may be determined based on the replacement temperature values of the regions which correspond to portions of the layer which are intended to fuse and those which are in the boundary zone.
  • FIG. 4 is another example of a method of additive manufacturing comprising, in block 402, measuring the temperature of a plurality of regions of the layer of build material in an additive manufacturing apparatus to provide initial temperature values. The operation may be carried out as described above in relation to block 102.
  • Block 404 comprises determining the size of a continuous area of the layer of build material which comprises build material which is intended to fuse. This may be determined based on control data, object model data, or thermal data such as measured temperature, as described above in relation to block 404. In some examples, there may be several regions which are intended to fuse and each of these regions may be considered individually.
  • Block 406 comprises comparing the size to a threshold size. In the event that the size is below the threshold size, the method proceeds with block 104 of FIG. 1. However, in the event that the size is above the threshold size, the method continues with block 408 which comprises using a linear regression and a predicted heat of each region based on data indicating the portions of the layer which are intended to fuse to estimate the representative temperature.
  • Therefore, in this example, there are two methods which may be used to replace data to determine a representative temperature. The method of FIG. 1 may be used for continuous regions up to a threshold size and the method of block 408 may be used for regions above this size. The threshold size may be determined for each of a plurality of print bed zones, the zones being associated with different heat sources.
  • FIG. 5 shows an example of a heat map of a zone of a layer of build material associated with a particular heat source in which a large proportion (the white portion) is intended to fuse. The zone may be one of, for example twelve zones of the layer.
  • In some examples, a predicted heat of each region may be determined based on an amount of print agent to be applied thereto and, in some examples, the predicted temperature of surrounding regions. When predicting temperatures, any optical distortion, for example due to fisheye lens(es) applied to the thermal camera, as is shown in FIG. 5, or the like, may be taken into account.
  • This can be used to determine a ‘grey level’ characterising the expected temperature of each pixel. In some examples, untreated powder may be associated with a grey level value of 0. However, as detailed above, in some examples detailing agent may be used to cool powder. Therefore, in some examples, the grey level associated with such detailing agents may for example be in the region of 0 to 20, the white powder may be associated with a grey level of around 20 to 25 (in some examples 23) and pixels associated with the application of fusing agent may be associated with higher grey level values. The grey levels for each pixel may then be plotted against the measured temperature value for that pixel. In some examples, an average of the measured temperatures for all pixels with a particular assigned grey level may be determined.
  • For example, in a particular zone it may be expected that eight pixels are associated with the temperature of blank build material (in this example grey level equal to 0), six pixels may be associated with a grey level of 9 (for example, this may represent pixels with some thermal contribution from adjacent pixels to which fusing agent has been applied), two pixels may be associated with a grey level of 28, two pixels may be associated with a grey level of 61 and one pixel may be associated with a grey level of 102 (i.e. a reasonably large amount of fusing agent may be applied to the region of the build material captured in that pixel). In this example, the average measured temperature of the pixels with a grey level of 0 is 154.50° C. The average measured temperature value of the pixels with a grey level of 9 is 156.00° C. The average measured temperature of the pixels with a grey level of 28 is 155.50° C. The measured temperature of the pixel with a grey level of 61 is 156.00° C. and the measured temperature of the pixel with a grey level of 102 is 157.00° C.
  • FIG. 6 shows a plot of these grey levels against the averages of the measured temperatures. The zero crossing point of a ‘best fit’ line provides the representative temperature in this example. Therefore, this method uses linear regression to determine the representative temperature.
  • In some examples, the linear regression may be carried out for a plurality of zones, each zone being associated with a different heat source. In one example, a linear regression may be carried out for each of a plurality of zones separately.
  • FIG. 7 is an example of an additive manufacturing apparatus 700 comprising processing circuitry 702, the processing circuitry 702 comprises a temperature determination module 704 and a controller 706.
  • The temperature determination module 704 is, in use of the apparatus, to determine a representative temperature of the layer of build material by replacing measured temperature values of a pixel of a heat map of the layer which comprises build material which is intended to fuse with average temperatures of neighbouring pixels. For example, this may comprise carrying out the methods of FIG. 1 and FIG. 2 described above.
  • The controller 706 is to control at least one heat source based on the representative temperature value of the layer of build material.
  • FIG. 8 shows an example of an additive manufacturing apparatus 800 comprising the processing circuitry 702 including the temperature determination module 704 and the controller 706 of FIG. 7. In addition, the additive manufacturing apparatus 800 comprises a plurality of heat sources 802 a-d and a print bed 804 (although it will be understood that the print bed 804 and/or the heat sources 802 a-d may be supplied separately from other additive manufacturing apparatus components).
  • The heat sources 802 are arranged in an array, each heat source 802 being associated with a zone of the print bed 804. In this example, the temperature determination module 704 is to determine a plurality of representative temperature is a different zones of a layer of build material and the controller 706 is to control a plurality of heat sources based on the representative temperature value for an associated zone.
  • In some examples, the additive manufacturing apparatus 700, 800 may comprise or otherwise be provided with or operate in association with temperature sensing apparatus. Such temperature sensing apparatus may for example comprise a thermal imaging camera to obtain a thermal image/heat map of the print bed, wherein the thermal image/heat map comprises a plurality of pixels, each pixel having an associated measured temperature. In other examples, temperature sensing apparatus may comprise a thermal imaging sensor array, or some other thermal sensing apparatus, and may be used to determine one or more temperatures (which may be pixels of a heat map).
  • The additive manufacturing apparatus 700, 800 may generate objects in a layer-wise manner by selectively solidifying portions of layers of build materials. The selective solidification may in some examples be achieved by selectively applying print agents, for example through use of ‘inkjet’ liquid distribution technologies, and applying energy, for example heat, to each layer. The additive manufacturing apparatus 700, 800 may comprise additional components not shown herein, for example a fabrication chamber, at least one print head for distributing print agents, a build material distribution system for providing layers of build material and the like.
  • The additive manufacturing apparatus 700, 800 may, in some examples, carry out at least one of the blocks of FIG. 1, 3 or 4.
  • FIG. 9 shows an example of a tangible machine readable medium 900 in association with a processor 902. The machine readable medium 900 stores instructions 904 which, when executed by the processor 902 cause the processor to carry out actions.
  • In this example, the instructions 904 comprise instructions 906 to identify, from a heat map of the layer of build material in an additive manufacturing apparatus comprising a plurality of pixels, the pixels which are directly indicative of a temperature of the layer in the absence of applied print agent, i.e. the blank pixels. The instructions 904 further comprise instructions 908 to cause the processor 902 to determine, for a plurality of pixels which are not directly indicative of a temperature of the layer in the absence of applied print agent (e.g. treated and/or edge pixels), an average temperature value of a plurality of neighbouring regions. The instructions 904 further comprise instructions 910 to cause the processor 902 to determine, based on the directly indicative pixels and the determined average temperature values, a representative temperature of an area of the layer of build material. The instructions 904 further comprise instructions 912 to cause the processor 902 to control a heat source based on the representative temperature.
  • In some examples, the instructions 906 may comprise instructions to determine the pixels based on data modelling the content of a fabrication chamber. In other examples, the blank pixels may be identified based on control data (for example specifying where print agents have been/are to be placed), and/or measured temperature values, for example based on threshold values.
  • In some examples, the instructions 908 to determine an average temperature value comprise, for at least one pixel which is not directly indicative of a temperature of the layer in the absence of applied print agent, instructions to determine a first average temperature value of a first plurality of neighbouring regions, and a second average temperature value of a second plurality of neighbouring regions.
  • In some examples, the instructions 904 may comprise instructions to cause the processor 902 to determine the size of a continuous set of pixels which are not directly indicative of a temperature of the layer in the absence of applied print agent, and when the area is below a threshold size, determining the average temperatures, and, when the area is at least a threshold size, using a linear regression and a predicted heat of each region to determine a representative temperature.
  • Examples in the present disclosure can be provided as methods, systems or machine readable instructions, such as any combination of software, hardware, firmware or the like. Such machine readable instructions may be included on a computer readable storage medium (including but not limited to disc storage, CD-ROM, optical storage, etc.) having computer readable program codes therein or thereon.
  • The present disclosure is described with reference to flow charts and block diagrams of the method, devices and systems according to examples of the present disclosure. Although the flow diagrams described above show a specific order of execution, the order of execution may differ from that which is depicted. Blocks described in relation to one flow chart may be combined with those of another flow chart. It shall be understood that at least some flows and/or blocks in the flow charts and/or block diagrams, as well as combinations of the flows and/or diagrams in the flow charts and/or block diagrams can be realized by machine readable instructions.
  • The machine readable instructions may, for example, be executed by a general purpose computer, a special purpose computer, an embedded processor or processors of other programmable data processing devices to realize the functions described in the description and diagrams. In particular, a processor or processing circuitry may execute the machine readable instructions. Thus functional modules of the apparatus (such as the temperature determination module 704 and the controller 706) may be implemented by a processor executing machine readable instructions stored in a memory, or a processor operating in accordance with instructions embedded in logic circuitry. The term ‘processor’ is to be interpreted broadly to include a CPU, processing unit, ASIC, logic unit, or programmable gate array etc. The methods and functional modules may all be performed by a single processor or divided amongst several processors.
  • Such machine readable instructions may also be stored in a computer readable storage that can guide the computer or other programmable data processing devices to operate in a specific mode.
  • Machine readable instructions may also be loaded onto a computer or other programmable data processing devices, so that the computer or other programmable data processing devices perform a series of operations to produce computer-implemented processing, thus the instructions executed on the computer or other programmable devices realize functions specified by flow(s) in the flow charts and/or block(s) in the block diagrams.
  • Further, the teachings herein may be implemented in the form of a computer software product, the computer software product being stored in a storage medium and comprising a plurality of instructions for making a computer device implement the methods recited in the examples of the present disclosure.
  • While the method, apparatus and related aspects have been described with reference to certain examples, various modifications, changes, omissions, and substitutions can be made without departing from the spirit of the present disclosure. It is intended, therefore, that the method, apparatus and related aspects be limited by the scope of the following claims and their equivalents. It should be noted that the above-mentioned examples illustrate rather than limit what is described herein, and that those skilled in the art will be able to design many alternative implementations without departing from the scope of the appended claims. Features described in relation to one example may be combined with features of another example.
  • The word “comprising” does not exclude the presence of elements other than those listed in a claim, “a” or “an” does not exclude a plurality, and a single processor or other unit may fulfil the functions of several units recited in the claims.
  • The features of any dependent claim may be combined with the features of any of the independent claims or other dependent claims, in any combination.

Claims (20)

1. Additive manufacturing apparatus comprising processing circuitry, the processing circuitry comprising:
a temperature determination module to determine a representative temperature value for a layer of build material by replacing measured temperature values of pixels from a plurality of regions of a heat map of the layer which comprise build material which is intended to fuse with average temperatures of neighboring pixels; and
a controller, to control a heat source based on the representative temperature value for a layer of build material.
2. Additive manufacturing apparatus of claim 1, in which the temperature determination module is to determine a plurality of representative temperatures for different zones of the layer, and the controller is to control each of a plurality of heat sources based on the representative temperature value for a zone associated with that heat source.
3. Additive manufacturing apparatus of claim 2, further comprising a plurality of heat sources.
4. A machine readable medium comprising instructions which, when executed by a processor, cause the processor to:
identify, from a heat map of a layer of build material in an additive manufacturing apparatus comprising a plurality of pixels, pixels which are directly indicative of a temperature of the layer in the absence of applied print agent;
for a plurality of pixels indicative of a temperature of a plurality of regions of the layer to be fused, determine an average temperature value of a plurality of neighbouring regions;
determine, based on the pixels which are directly indicative of a temperature of the layer in the absence of applied print agent and the determined average temperature values, a representative temperature of an area of the layer of build material; and
control a heat source based on the representative temperature.
5. A machine readable medium of claim 4, wherein the instructions to identify the pixels which are directly indicative of a temperature of the layer in the absence of applied print agent comprise instructions to identify the pixels based on data modelling a content of a fabrication chamber.
6. A machine readable medium of claim 4, wherein the instructions to determine an average temperature value comprise, for at least one pixel which is not directly indicative of a temperature of the layer in the absence of applied print agent, instructions to determine a first average temperature value of a first plurality of neighbouring regions and a second average temperature value of a second plurality of neighbouring regions.
7. A machine readable medium of claim 4, further comprising instructions to determine a size of a continuous set of pixels which are not directly indicative of a temperature of the layer in the absence of applied print agent; and
when the area is below a threshold size, to determine the average temperature values, and, when the area is at least a threshold size, to use a linear regression and a predicted heat of each region to determine a representative temperature.
8. An additive manufacturing apparatus comprising:
An array of temperature sensors for measuring a temperature of a plurality of regions of a layer of build material in an additive manufacturing apparatus to provide initial temperature values;
processing circuitry comprising a temperature determination module for
determining, for each of a plurality of regions which comprise build material which is intended to fuse, an average temperature value of a plurality of neighboring regions,
replacing the initial temperature values with the average temperature values, and
determining, based on the replacement temperature values, a representative temperature of an area of the layer of build material; and
a controller for controlling a heat source based on the representative temperature.
9. The additive manufacturing apparatus of claim 8, wherein the temperature determination module is programmed to determine the representative temperature using:
a first iteration, for a plurality of regions, determining a first replacement temperature value comprising an average value of neighboring regions on a first and second side of a region; and
a second iteration, for a plurality of regions, determining a second replacement temperature value comprising an average value of neighboring regions on a third and fourth side of a region,
wherein the representative temperature is based on the second replacement temperature values.
10. The additive manufacturing apparatus of claim 8, wherein the temperature determination module is further programmed for:
determining an indication of a size of a continuous area of the layer of build material which comprises build material which is intended to fuse, and
determining the replacement temperature values for the area when it is determined that the continuous area is below a threshold size.
11. The additive manufacturing apparatus of claim 10, further comprising, when the temperature determination module determines that the continuous area is above a threshold size, the temperature determination module is programmed to use a linear regression and a predicted heat of each region based on data indicating portions of the layer which are intended to fuse to estimate the representative temperature.
12. The additive manufacturing apparatus of claim 8, wherein the average temperatures value is a weighted average, wherein at least one weighting is indicative of whether the temperature value of a neighboring region is an initial value or a replacement value.
13. The additive manufacturing apparatus of claim 12, wherein the weighting is indicative of how many initial values were used in determining a replacement value of that region.
14. The additive manufacturing apparatus of claim 8, wherein the temperature determination module is further programmed to:
determine, for each of a plurality of regions which are in a boundary zone of the layer, an average temperature value of a plurality of neighboring regions; and
replace the initial temperature values with the average temperature values,
wherein determining, based on the replacement temperature values, a representative temperature of an area of the layer of build material comprises determining the temperature based on the replacement temperature values of the regions in the boundary zone.
15. The additive manufacturing apparatus of claim 8, wherein:
the temperature determination module is programmed to determine a representative temperature for each of a plurality of print bed zones; and
the controller is programmed to control a plurality of heat sources based on the representative temperature of an associated print bed zone.
16. The additive manufacturing apparatus of claim 8, wherein the temperature determination module is programmed to determine each pixel of a thermal image of the layer of build material is used as a region for which the average temperature value of a plurality of neighboring regions, an initial temperature value for a number of the pixels being replaced with such an average temperature value.
17. The additive manufacturing apparatus of claim 16, f wherein the temperature determination module is programmed to determine an average temperature value to replace an initial temperature value for each pixel in a sweep pattern from a first corner of the thermal image to an opposite corner of the thermal image.
18. The additive manufacturing apparatus of claim 8, wherein each area for which a representative temperature is determined comprises a plurality of the regions for which a replacement temperature is determined, each area corresponding to a different heat source among a plurality of heat sources.
19. The additive manufacturing apparatus of claim 8, wherein temperature determination module is further programmed to determine each of the plurality of regions which comprise build material which is intended to fuse using control data that instructs distribution of print agents.
20. The additive manufacturing apparatus of claim 19, wherein temperature determination module is further programmed to perform a second iteration of determining an average temperature value to replace a current temperature value for each pixel in a second sweep pattern from the opposite corner of the thermal image back to the first corner of the thermal image.
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