US 11,679,565 B2
Additive manufacturing system and method and feature extraction method
Haw-Ching Yang, Tainan (TW); Yu-Lung Lo, Tainan (TW); Hung-Chang Hsiao, Tainan (TW); Shyh-Hau Wang, Tainan (TW); Min-Chun Hu, Tainan (TW); Chih-Hung Huang, Tainan (TW); and Fan-Tien Cheng, Tainan (TW)
Assigned to NATIONAL CHENG KUNG UNIVERSITY, Tainan (TW)
Filed by NATIONAL CHENG KUNG UNIVERSITY, Tainan (TW)
Filed on Jun. 6, 2022, as Appl. No. 17/805,469.
Application 17/805,469 is a division of application No. 16/591,613, filed on Oct. 2, 2019, granted, now 11,383,446.
Claims priority of provisional application 62/740,435, filed on Oct. 3, 2018.
Claims priority of provisional application 62/808,865, filed on Feb. 22, 2019.
Prior Publication US 2022/0297383 A1, Sep. 22, 2022
Int. Cl. B29C 64/393 (2017.01); B33Y 10/00 (2015.01); G05B 19/4099 (2006.01); B29C 64/153 (2017.01); B23K 26/342 (2014.01); B33Y 30/00 (2015.01); B33Y 50/02 (2015.01); B22F 1/142 (2022.01); B22F 10/28 (2021.01); B22F 12/90 (2021.01); B22F 10/368 (2021.01); B22F 10/85 (2021.01); B29K 105/00 (2006.01); B22F 12/82 (2021.01); B22F 10/36 (2021.01); B22F 10/80 (2021.01)
CPC B33Y 10/00 (2014.12) [B22F 1/142 (2022.01); B22F 10/28 (2021.01); B22F 10/368 (2021.01); B22F 10/85 (2021.01); B22F 12/90 (2021.01); B23K 26/342 (2015.10); B29C 64/153 (2017.08); B29C 64/393 (2017.08); B33Y 30/00 (2014.12); B33Y 50/02 (2014.12); G05B 19/4099 (2013.01); B22F 10/36 (2021.01); B22F 10/80 (2021.01); B22F 12/82 (2021.01); B29K 2105/251 (2013.01); G05B 2219/49023 (2013.01)] 6 Claims
OG exemplary drawing
 
1. An additive manufacturing (AM) method, comprising:
using an AM tool to fabricate a plurality of workpiece products, wherein the workpiece products are divided into a plurality of first workpiece products and a second workpiece product, and the second workpiece product is fabricated after the first workpiece products, an operation of fabricating each of the workpiece products comprising:
placing a powder layer on a powder bed; and
directing an energy beam to a plurality of powder bodies on the powder layer sequentially to melt powder bodies to form a plurality of melt pools;
measuring qualities of the first workpiece products respectively after the first workpiece products are completely fabricated, thereby obtaining a plurality of actual metrology values of the first workpiece products;
performing a temperature measurement on each of the melt pools on the powder bed during a fabrication of each of the workpiece products, thereby obtaining a temperature of each of the melt pools of each of the workpiece products;
performing photography on each of the melt pools on the powder bed during the fabrication of each of the workpiece products, thereby obtaining an image of each of the melt pools of each of the workpiece products;
extracting a length and a width of each of the melt pools from the image of each of the melt pools;
performing a melt-pool feature processing operation to convert the length, the width and the temperature of each of the melt pools to a melt-pool length feature, a melt-pool width feature and a melt-pool temperature feature of each of the workpiece products;
building a conjecture model by using a plurality of sets of first process data and the actual metrology values of the first workpiece products in accordance with a prediction algorithm, the sets of first process data comprising the melt-pool length feature, the melt-pool width feature and the melt-pool temperature feature of each of the first workpiece products; and
predicting a virtual metrology value of the second workpiece product by using the conjecture model based on a set of second process data, the set of second process data comprising the melt-pool length feature, the melt-pool width feature and the melt-pool temperature feature of the second workpiece product.