Computed tomography as distortion mitigation method for selective laser sintering mass production

Abstract

Most additive manufacturing (AM) technologies use heat to fuse materials together to create the manufactured part. The heat used in the AM process distorts the parts. Powder bed–based 3D printers can print multiple parts in their build chamber. The distortion is not uniform across the different locations of the build volume. Parts printed in different locations will have different thermal histories and therefore different distortions. In some cases, the achievable accuracy of the parts is insufficient due to the distortion. Subtractive processes such as milling, turning, and grinding make it difficult or impossible to improve part accuracy. For AM to produce more accurate parts, a distortion reduction method must be implemented. To take advantage of the ability to print multiple parts in a powder-based polymer 3D printing process in one build unit, a distortion mitigation technique must be applied to all the parts being printed simultaneously in the build chamber. The performance of the distortion mitigation method can be evaluated by measuring the dimensional accuracy of the uncompensated and compensated parts. Uncompensated 3D printing uses the nominal 3D model, which is the normal use of the 3D printers. Compensated 3D printing uses a distorted 3D model that is used for the printing. The 3D model is compensated with the reversed distortion data obtained from uncompensated manufacturing. X-ray computed tomography (XCT) is the chosen measurement method to extract the point cloud for the dimensional measurements. Unlike optical 3D scanners and coordinate measuring machines (CMM), the XCT is able to measure undercut and internal surfaces. The nominal difference % is improved by 18% by using compensation for the 3D models in the case of distances between two parallel planes. The standard deviation of the measured values was also improved. The distortion reduction method studied can significantly reduce the calibration errors of the 3D printer build chamber. When the tolerances of the parts are close to the limit of the 3D printer, this method can reduce the number of rejected parts. The XCT measurement of the parts is costly, so this method can be cost effective for high value parts or large production volumes.