Predictive modeling of in-plane geometric deviation for 3D printed freeform products

Luan, He; Huang, Qiang

doi:10.1109/coase.2015.7294215

Cited by 17 publications

(10 citation statements)

References 13 publications

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“…Huang et al (2015) analyzed the in-plane ( x and y ) shape deformation and illustrated their approach for the cylindrical shapes in the SLA process. Huang et al (2014) and Luan and Huang (2015) later extended their previous study to polygon shape and arbitrary free-form shape deviations in SLA process, respectively. Based on the previous work in in-plane geometric deformation, Jin et al (2015) extended the methodology to the out-of-plane ( z ) geometric error prediction for SLA process.…”

Section: Literature Reviewmentioning

confidence: 92%

“…Paul et al (2014) and Paul and Anand (2015) studied the effect of thermal deformation and applied the optimization method to calculate the optimal values of slice thickness and part orientation aiming to increase part strength and reduce sintering energy. Huang and colleagues (Huang et al , 2014, 2015, Luan and Huang, 2015; Huang, 2016) have recently established a novel approach to model and predict part deviations from shrinkage deformation and derive an optimal compensation plan to achieve dimensional accuracy using the polar coordinates system ( r , θ and z ). Huang et al (2015) analyzed the in-plane ( x and y ) shape deformation and illustrated their approach for the cylindrical shapes in the SLA process.…”

Section: Literature Reviewmentioning

confidence: 99%

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A dimensional compensation algorithm for vertical bending deformation of 3D printed parts in selective laser sintering

Ransikarbum

Han

et al. 2018

RPJ

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Purpose The purpose of this study is to mitigate the dimensional inaccuracy due to vertical curling/bending deformation of three-dimensional (3D) printed parts produced by selective laser sintering (SLS) using PA12 based on dimensional compensation of the computer-aided design (CAD) model. Design/methodology/approach To carry out this study, specially designed features are initially produced as references, and the dimensional deviations from the vertical bending deformation of the SLS process are analyzed. Next, the deformation patterns are formulated using a polynomial regression model in the global Cartesian coordinates of the building platform. Then, the compensation algorithm is implemented and the original 3D CAD file is preprocessed with an inverse transformation of the features to compensate the deformation errors. Findings It was found that the 3D printed parts from the SLS process have the dimensional inaccuracy due to the vertical bending pattern of the quadratic form. By implementing the compensation algorithm, it was statistically shown to effectively reduce bending deformations of various sample parts, including the automotive components, in SLS. Research limitations/implications The position of samples in a batch has a direct impact on not only bending deformation but also on horizontal shape geometry error. However, the application of this algorithm is focused on the vertical bending deformation, which is estimated as a major part of dimensional inaccuracy. Practical implications This paper provides a practical case study with a real vehicle part. The algorithm was shown to provide a more realistic solution to the dimensional deformation of printed products, which is not manageable by simply using the constant scale factors provided by SLS 3D printer manufacturers. Originality/value This paper suggests that the vertical bending deformation from SLS’s 3D printed complex parts can be improved through the proposed compensation algorithm. The compensation algorithm was constructed by using the predictive regression model created from the bending deformation patterns of reference samples. The proposed compensation algorithm can be further used and applied for other complex samples without making additional reference parts.

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Section: Literature Reviewmentioning

confidence: 92%

Section: Literature Reviewmentioning

confidence: 99%

A dimensional compensation algorithm for vertical bending deformation of 3D printed parts in selective laser sintering

Ransikarbum

Han

et al. 2018

RPJ

View full text Add to dashboard Cite

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“…This function is defined as a periodic waveform that can be modified according to the polyhedron shape. Later, this model is further extended to freeform shapes [12]. The freeform shape is approximated either by a polygon using the Polygon Approximation with Local Compensation (PALC) strategy or by addition of circular sectors using the Circular Approximation with Selective Cornering (CASC) strategy.…”

Section: Compensation Of Shape Deviationsmentioning

confidence: 99%

Review of Shape Deviation Modeling for Additive Manufacturing

Zhu

Keimasi

Anwer

et al. 2016

Lecture Notes in Mechanical Engineering

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International audienceAdditive Manufacturing (AM) is becoming a promising technology capable of building complex customized parts with internal geometries and graded material by stacking up thin individual layers. However, a comprehensive geometric model for Additive Manufacturing is not mature yet. Dimensional and form accuracy and surface finish are still a bottleneck for AM regarding quality control. In this paper, an up-to-date review is drawn on methods and approaches that have been developed to model and predict shape deviations in AM and to improve geometric quality of AM processes. A number of concluding remarks are made and the Skin Model Shapes Paradigm is introduced to be a promising framework for integration of shape deviations in product development, and the digital thread in AM

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“…Huang and co-workers [30][31][32]39] improved the offline shape shrinkage compensation using Fourier series parameterisation. The authors started from compensating cylindrical shapes to including more complex shapes such as polyhedrons [33], and further established a 3D geometric compensation and derivation of the optimal amount of compensation [34]. They also adopted polygon approximation with local compensation and circular approximation with selective corning to predict deviations of free-form shapes.…”

Section: Introductionmentioning

confidence: 99%

Artificial neural network-based geometry compensation to improve the printing accuracy of selective laser melting fabricated sub-millimetre overhang trusses

Hong

Zhang

Lifton³

et al. 2021

Additive Manufacturing

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Selective laser melting processes deposit and join metal powders to near net shape in a layerby-layer manner. The process of melting and re-solidification of several layers of deposited material can result in geometric deviations, and the impact is particularly significant for submillimetre structures oriented at a wide range of overhang angles with respect to the building platform. This paper assesses and benchmarks the capabilities of a neural network-based geometric compensation approach for truss lattice structures with circular cross-sections. The neural network method is capable to generate free-form cross-sections with enhanced geometric freedom for compensation compared to more established analytical compensation approaches limited to predefined geometric shapes. For neural network training, lattice dome structures composed of trusses with different overhang angles were designed and printed by selective laser melting and measured via X-ray computed tomography, resulting in point cloud data sets containing more than 20,000 data points for each overhang angle. For experimental validation, neural network-compensated dome structures were benchmarked against dome structures with elliptical parameter compensation. Results show that the neural network compensated lattice trusses achieve higher printing dimensional accuracy compared to the uncompensated structures and those compensated based on elliptical parameter estimates.

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Predictive modeling of in-plane geometric deviation for 3D printed freeform products

Cited by 17 publications

References 13 publications

A dimensional compensation algorithm for vertical bending deformation of 3D printed parts in selective laser sintering

A dimensional compensation algorithm for vertical bending deformation of 3D printed parts in selective laser sintering

Review of Shape Deviation Modeling for Additive Manufacturing

Artificial neural network-based geometry compensation to improve the printing accuracy of selective laser melting fabricated sub-millimetre overhang trusses

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