Compensation for Geometrical Deviations in Additive Manufacturing

Abstract

The design of additive manufacturing processes, especially for batch production in industrial practice, is of high importance for the propagation of new additive manufacturing technology. Manual redesign procedures of the additive manufactured parts based on discrete measurement data or numerical meshes are error prone and hardly automatable. To achieve the required final accuracy of the parts, often, various iterations are necessary. To address these issues, a data-driven geometrical compensation approach is proposed that adapts concepts from forming technology. The measurement information of a first calibration cycle of manufactured parts is the basis of the approach. Through non-rigid transformations of the part geometry, a new shape for the subsequent additive manufacturing process was derived in a systematic way. Based on a purely geometrical approach, the systematic portion of part deviations can be compensated. The proposed concept is presented first and was applied to a sample fin-shaped part. The deviation data of three manufacturing cycles was utilised for validation and verification.

A Design for Additive Manufacturing Strategy for Dimensional and Geometrical Quality Improvement of PolyJet-Manufactured Glossy Cylindrical Features

“…As a difference with previous research studies [ 16 , 29 , 37 , 39 , 42 ], the achieved improvements did not require dense digitizing, neither required of deviation adjustment models [ 29 ] or interpolation procedures [ 28 , 42 ] to accurately map form errors. Instead, a bi-univocal correspondence between verification points and design parameterization has proven to be a valid option.…”

“…Additionally, they have made attempts to extend 2D compensation to 3D compensation by dividing the problem into in-plane deformation (concerning the cross-section) and out-of-plane deformation [ 35 , 36 ]. Deviation models have sometimes been obtained from large amounts of data [ 37 , 38 , 39 ], especially when 3D optical scanning instruments were used for geometrical characterization of parts, but also when models obtained through finite elements analysis [ 38 , 40 ] were used. Some of these works proposed a pre-distortion of the input files to compensate for form errors, which has been highlighted as a relevant strategy for quality control in AM [ 41 ].…”

“…Even in those cases where the reference geometry has been already parameterized to model geometrical distortion [ 40 ], a fitting procedure between the information from distorted geometry and the original geometry was carried out. Moreover, some works [ 12 , 39 ] showed that parameters related to production planning, like the position or orientation of a given part within the manufacturing space, could have an influence upon the modelling of geometrical deviations. Nevertheless, most compensation models did not usually take this fact into account.…”

Investigation of Laser Polishing of Four Selective Laser Melting Alloy Samples

“…The structure of the samples was simple and the height was very low, so the position may have a little influence on the global geometry. Therefore, a systematic compensation approach from forming technology presented by Hartmann et al [29] has not been considered. The particle diameter of the metal powders (Advanced Powders and Coatings Inc., Boisbriand, Québec, Canada) used in the present study was 15-45 µm.…”

Editorial for the Special Issue “Reviews and Advances in Materials Processing”

“…Different processing variations were attempted and strength was characterized to understand the effects of these variations. Hartmann et al [11] highlighted the importance of the design of the additive manufacturing process in the context of industrial adaptability. In their article, they proposed a data-driven geometrical compensation approach.…”