Preventing Layering Defects in 3D Printing Techniques

3D printing metal objects without warping or cracking by using a tacky polymer substrate. The process involves spreading a layer of metal particles over a polymer substrate with low thermal conductivity and melting the unmasked metal with pulsed light to form each layer of the object. The polymer substrate reduces lateral heat transfer during melting, preventing warping and cracking.

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Using a statistical learning model to inspect camera images of each layer during 3D printing to detect layer defects early and correct them before building on top. The model provides defect probabilities for each image pixel. If defects are found, the layer is reworked.

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3D printing of parts with improved mechanical properties and reduced warping. The method involves using a photopolymer composite ink with a dual-cure system that enables complete curing of each layer in a 3D printed object. The composite consists of a polymer matrix, inorganic fillers, and a combination of photo and thermal initiators. The dual-cure initiators allow the composite to be partially cured by UV light after each layer is printed and then fully cured by heat. This prevents uncured resin from accumulating stress and warping the part.

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In-situ quality testing of additively manufactured components during production to detect defects like cracks or delamination and prevent fabrication of flawed parts. The process involves mechanically exciting constructed layers of the component and measuring the mechanical response. If the response deviates from a tolerance range, indicating flaws, the production is halted. Excitation can be done using vibrations or oscillations and measurement can use pickups or sensors.

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Additive manufacturing system that can detect and prevent defects during 3D printing to improve the quality of the printed objects. It does this by incorporating an in-line measurement unit that measures each layer as it is printed. The system then compares the layer measurements against reference data of a known good object to detect any deviations that could indicate an internal defect. This allows defects to be caught and corrected during the printing process rather than after completion.

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Selective laser melting (SLM) additive manufacturing system that monitors layer-by-layer manufacturing of a product and adjusts control parameters during manufacturing to correct defects. It captures images of each layer before adding the next layer and then analyzes the images to identify irregularities. If found, it adjusts the laser parameters for the next layer to avoid defects like balling.

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Reducing errors in 3D printing by dynamically adjusting printer parameters based on the printed object geometry. The method involves identifying areas prone to printing defects, like gaps or under/over extrusion, and adjusting printing speed, extrusion rate, and linewidth in those areas to compensate. The adjustments are made using a model that predicts where defects are likely to occur based on the printing path. This allows customizing printer kinematics to prevent internal defects without sacrificing speed.

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3D printing method to create objects with good transparency and eliminate the need for support structures. It involves curing the printed layers while still viscous to bond them together instead of waiting for complete curing. This is achieved by controlling factors like UV intensity, irradiation time, and layer formation timing. This prevents gaps and voids between layers and reduces "lamination marks" for smoother surfaces. It also enables creating transparent objects without support materials.

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3D printing method and system that dynamically adjusts the surface roughness of printed layers during multi-layer 3D printing to improve bonding between adjacent layers. After printing a layer, a surface modification component is used to add roughness if necessary based on parameters and detected features. This allows optimizing the surface texture for each layer to enhance layer adhesion.

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3D printing system with improved layer fusion and printing quality. It uses preheating and flattening systems on both sides of the print head to better fuse the printed layers. The system has two layer processing systems, one on each side of the print head, that move synchronously with the print head. Each system has a preheating apparatus to warm the previous layer before printing the next layer. This raises the previous layer temperature to better fuse with the new layer. After printing, a flattening roller on the opposite side compresses the layer to remove warping. The roller also cools the layer. By preheating and flattening on both sides, it improves layer fusion, reduces warping, and enhances print quality.

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3D printing control execution method to improve accuracy and reduce waste by detecting and adjusting printing errors. After each layer, actual images are analyzed versus theoretical ones to find position and height errors. If exceeding thresholds, stop printing and provide feedback. If within thresholds, adjust parameters for next layer. This allows catching and correcting errors before they accumulate in the final model.

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A method for processing 3D printed objects during the printing process itself to avoid defects and scraping after completion. The method involves detecting if the adhesive glue used between layers is solidifying properly. If not, it prevents further powder spraying and skips to the next layer. This avoids incomplete adhesion and powder detachment issues that can occur during rapid 3D printing. By detecting during printing instead of post-processing, it ensures a solidified glue layer before continuing.

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3D printing system and method to improve quality and accuracy of 3D prints by optimizing layer adhesion and cooling. The system uses preheating and flattening mechanisms on either side of the extruder that engage based on extruder movement. When the extruder moves to one side, the preheater there heats the upper layer before printing, while the flattener on the other side remains off. Then when the extruder moves back, the preheater there is off and the flattener engages to flatten the printed layer. This prevents deformation of the upper layer while printing, improves fusion, and speeds cooling by contact.

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A loading system for 3D printers that reduces mounding and increases the uniformity of powder layers. The system has a loading chamber positioned over the supply container. Powder is dispensed into the chamber and compacted to increase uniformity. The chamber floor is then lowered into the supply container, transferring the compacted powder. This loading process helps distribute the powder more evenly throughout the container compared to filling it directly.

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A real-time multi-parameter matching continuous fiber reinforced composite material 3D printing assisted forming process that improves the bonding strength between layers of 3D printed composite components. The process involves coordinated adjustment of external temperature and pressure during printing based on feedback to match the material properties. An auxiliary heating mechanism and pressure application mechanism are activated during printing to reduce temperature differences, increase forming pressure, and enhance interlayer bonding. The auxiliary mechanisms are synchronized with the printer motion to enable continuous multi-parameter 3D printing.

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Real-time monitoring and control system for 3D printers used in construction that improves quality and safety by measuring and responding to properties of the extruded material and stacked layers during printing. The system uses sensors around the print head to acquire quality data like height, extrusion amount, defects, and cross-section. An algorithm processes this real-time feedback to calculate optimal print parameters like height, speed, and mixing ratio. This allows the printer to adapt to changing material properties, prevent sagging, and avoid over/under extrusion. It also enables monitoring and control of critical features like layer thickness and shape.

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3D printing method to improve the strength and bonding of printed parts by interlayer stitching. The method involves forming an interlayer binding layer between adjacent layers during 3D printing. The binding layer extends into both lower and upper layers. It uses a one-dimensional material like carbon nanotubes or metal fibers that are injected into the lower layer and then extend into the upper layer when printing. This interlayer stitching significantly improves the bonding force and effect between layers, which enhances the overall strength of 3D printed parts.

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Additive manufacturing monitoring and control method to improve 3D printing reliability by detecting abnormalities during printing and remediating them. The method involves continuously acquiring key feature data like 3D point cloud, images, temperatures, and positions during printing. It judges if completed layers are normal, and if not, determines if the abnormality can be remedied. For salvageable abnormalities, it generates lower-level remedial printing paths without the issue. For unsalvageable abnormalities, it terminates printing. It also adjusts printing parameters in real-time based on the feature data.

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Controlling the microstructure uniformity of additive manufacturing components to improve their properties by using a multi-physics coupling approach to mitigate thermal accumulation effects. The method involves calculating the temperature, stress/strain, and microstructure fields during additive manufacturing using numerical simulation. By optimizing process parameters based on the temperature predictions, the microstructure can be more homogenized to prevent defects like porosity and cracks. This allows predicting and controlling the microstructure without expensive, time-consuming experiments.

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Adapting printing parameters during additive manufacturing processes to improve print quality and reliability. The technique involves monitoring the printing process in real-time and making adjustments to parameters like layer thickness, material deposition rate, and curing conditions based on detected deviations from the intended print path. This allows compensating for issues like misalignment, distortion, or inconsistencies in the print material. By dynamically adapting the printing parameters as needed, the technique aims to mitigate defects and improve the final printed object's quality.

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