Large format 3d printing augmented with 3d scanning and anomoly tracking feedback

{
  "publication_number": "US2018361729A1",
  "country": "US",
  "kind": "A1",
  "title": "Large format 3d printing augmented with 3d scanning and anomoly tracking feedback",
  "abstract": "The disclosure is directed at a system, apparatus and method for 3D printing an object using an industrial robot; such object is larger and may be more accurate than the print volume and accuracy of the industrial robot that is performing the print. The system is further capable of scanning the irregular 3D surface of the printing platform in which to create the 3D object and adapt the toolpath to print on this surface. The system is further capable of scanning the 3D surface of a specimen that is larger than the print volume of the industrial robot and make a scaled copy larger or smaller. The system is also capable of monitoring the quality of the object being printed while the print is in process.",
  "claims": [
    "1. A system for large format three-dimensional (3D) printing of an object comprising: a processing unit; a tracking system; a 3D printer including a set of components; and a set of trackers in a one-to-one relationship with the set of components, each of the set of trackers defining a local coordinate system for the associated component; wherein the tracking system communicates with the set of trackers to obtain information relating to the local coordinate systems; and wherein the processing unit calculates positions for the set of components within a global coordinate system based on the local coordinate systems. 2. The system of claim 1 wherein the tracking system is an optical six-dimensional (6D) tracking system. 3. The system of claim 2 wherein the 6D tracking system operates based on mechanical positioning constraints. 4. The system of claim 2 wherein the 6D tracking system is a magnetic system. 5. The system of claim 1 wherein the set of components comprises: an industrial robot component; a platform component; and a print head component mounted to the industrial robot component; wherein the industrial robot component controls movement of the print head with respect to the platform component. 6. The system of claim 5 wherein the set of components further comprises: a scanning apparatus. 7. The system of claim 6 wherein the set of components further comprises: a robotic arm for controlling movement of and supporting the scanning apparatus. 8. The system of claim 5 wherein the set of components further comprises: a set of anomaly sensor tracking components. 9. The system of claim 8 wherein the set of anomaly sensor tracking components comprises: a camera; and a robot to control the camera. 10. The system of claim 1 wherein the processing unit transmits printing instructions to the 3D printer based on the local coordinate systems and measurements of a scanned specimen. 11. A method of large format three-dimensional (3D) printing and scanning comprising: determining a global coordinate system; receiving local coordinate systems for selected components of a 3D printer; transforming each of the local coordinate systems to equivalents within the global coordinate system; obtaining measurements of a scanned specimen to be printed; combining the measurements and characteristics of the aligned local coordinate systems to generate printing instructions; and transmitting printing instructions to the 3D printer. 12. The method of claim 11 wherein determining a global coordinate system comprises: retrieving coordinate system information from a tracker associated with an object being printed. 13. The method of claim 11 wherein receiving local coordinate systems comprises: retrieving coordinate system information from trackers associated with components of the 3D printer. 14. The method of claim 13 wherein retrieving coordinate system information is performed magnetically."
  ],
  "description_excerpt": "This disclosure relates generally to the field of additive manufacturing, and more specifically, to a method and apparatus for large format three-dimensional (3D) printing.\n\nAs computers within manufacturing have advanced, so have methods of producing three-dimensional (3D) computer models and the ability to manufacture these models into printed objects using rapid prototyping techniques. Additive manufacturing is one of these techniques.\n\nIt is well known in the art how to produce fused deposition printers typically using a Cartesian style industrial robot. An example of this type of robotic printer is MakerBot™ Industries' Replicator. When printing an object, these robotic printers typically apply a very thin layer of material in the XY plane. The object is then moved relative to the print head in the Z direction and another layer is added. This continues until the 3D object is completely printed. This method is well suited to complex geometries that would be difficult to manufacture using subtractive techniques, such as with a computer numerical control (CNC) milling machine. There are also well known methods of using robotic arms and delta robots to move the print head (relative the object being printed), but due to the complex parallel movements, the accuracy printed object may be affected. The accuracy of the position of the print head greatly effects the accuracy of the final printed object. In order to improve accuracy, higher accuracy robot arms are typically used which increase the cost and complexity of the overall robotic printing system.",
  "cpc": [
    "B33Y 30/00",
    "B25J 9/1697",
    "B29C 64/118",
    "B29C 64/232",
    "B29C 64/236",
    "B29C 64/241",
    "B29C 64/393",
    "B33Y 10/00",
    "B33Y 50/02",
    "G01B 11/002",
    "G01B 11/24",
    "G01B 11/2518",
    "G01S 17/42",
    "G01S 17/74",
    "G01S 17/88",
    "G01S 17/89",
    "G06F 17/50",
    "G06F 30/00"
  ],
  "ipc": [
    "B25J 9/16",
    "B33Y 10/00",
    "B33Y 30/00",
    "B33Y 50/02",
    "G06F 17/50"
  ],
  "assignees": [
    "Ord Solutions Inc"
  ],
  "inventors": [
    "Christopher John Elmer GIBSON",
    "Peter Eldon Leis"
  ],
  "filing_date": "2016-12-15",
  "publication_date": "2018-12-20",
  "priority_date": "2015-12-21",
  "application_number": "US-201616060949-A",
  "family_id": "59088680",
  "cited_by_count": 38
}