Early notification system of degradation of 3D printed parts

In an approach for early notification of degradation of 3D printed parts, a processor completes an initial scan of a 3D printed part using backscatter techniques when the 3D printed part is installed and idle in the unit. A processor completes a second scan of the 3D printed part using backscatter techniques when the unit is in operation. A processor determines a baseline delta between the initial scan and the second scan. A processor performs an additional scan after a preset time interval of the 3D printed part using backscatter techniques in operation within the unit. A processor determines whether the additional scan is within the baseline delta.

BACKGROUND OF THE INVENTION

The present invention relates generally to the field of three-dimensional (3D) printing, and more particularly to an early notification system of degradation of 3D printed parts.

3D printing, or additive manufacturing, is the construction of a three-dimensional (3D) object from a computer-aided design (CAD) model, via a 3D scanner, or by a plain digital camera and photogrammetry software. The term “3D printing” can refer to a variety of processes in which material is deposited, joined, or solidified under computer control to create a three-dimensional object, with material being added together (such as plastics, liquids or powder grains being fused together), typically layer by layer.

SUMMARY

Aspects of an embodiment of the present invention disclose a method, computer program product, and computer system for early notification of degradation of 3D printed parts. A processor completes an initial scan of a 3D printed part using backscatter techniques when the 3D printed part is installed and idle in the unit. A processor completes a second scan of the 3D printed part using backscatter techniques when the unit is in operation. A processor determines a baseline delta between the initial scan and the second scan. A processor performs an additional scan after a preset time interval of the 3D printed part using backscatter techniques in operation within the unit. A processor determines whether the additional scan is within the baseline delta.

DETAILED DESCRIPTION

Embodiments of the present invention recognize that 3D printing has become a common practice in many industries, but the main issue holding some companies back from implementing this technology is the reliability of 3D printed parts. Most 3D printed parts do not pass an extensive stress test, so there is a high likelihood that the part will break or malfunction at some time potentially causing machine downtime, which can be costly for companies. Embodiments of the present invention recognize the need for self-monitoring capabilities by 3D printed parts, so that a 3D printed part can autonomously inform if there is any unexpected degradation of the part that may impact its functionality, efficiency, and longevity.

Embodiments of the present invention provide a system and method for analyzing the degradation of a 3D printed part to determine potential and upcoming errors or malfunctions and autonomously communicating the problem in real time without a power source. Embodiments of the present invention identify damage to certain 3D printed components in a system without the use of internal mechanisms. Embodiments of the present invention monitor for failure scenarios in a part or mechanism by using multiple frequencies to scan multiple parts simultaneously.

Embodiments of the present invention employ backscatter techniques to allow 3D printed parts to communicate with Wi-Fi® receivers autonomously. Backscatter is the reflection of waves, particles, or signals back to the direction from which they came. Thus, backscatter techniques are used herein to scan a 3D printed part before and during its operation in a system and identify degradation of the 3D printed part. For example, one backscatter technique uses an antenna to transmit data by reflecting radio signals emitted by a Wi-Fi® router or another device. Information embedded in the reflected radio signals can then be decoded by a Wi-Fi® receiver. The antenna is contained in a 3D printed object made of conductive printing filament that mixes plastic with copper. Embodiments of the present invention that utilize this technique must baseline the 3D printed part prior to setup to ensure that the backscatter reflection is absorbed by the amount of surface coating of nonconductive material.

Any change on the physical structure of the 3D printed object will expose part of the conductive material and case a conductive switch to intermittently connect or disconnect with the antenna and change its reflective state. The system will manage states one (1) and zero (0), and the states will switch based on the reflective state. A zero (0) state denotes no changes on the composition of the 3D printed object. A one (1) state denotes that conductive material has been exposed, i.e., a change to the surface of the 3D printed object.

In this system, a 3D printed object is printed using a multi-material print. The print has a metallic filament print engulfed between layers of non-metallic compound as known to a person of skill in the art. The metallic filaments reside engulfed in non-metallic casing, as the exposure of this metallic filament results in a positive antenna feedback, i.e., a one (1) state as described above. At least two layers of thickness is needed between metallic filaments to ensure they are properly isolated from each other and from an external wall of the object. All of these settings can be included in a 3D print data file. Once the 3D printed object is ready and has been inspected, the 3D printed object is placed into operation, and if it is a part of a larger machine or unit, the 3D printed object is placed in its designated position within the unit.

Embodiments of the present invention complete an initial scan (i.e., take a backscatter image) of the 3D printed object and/or the unit to identify the backscatter form (i.e., shape) of the unit. Embodiments of the present invention complete a second scan of the 3D printed object and/or the unit once the unit is placed into operation. The backscatter images are used to identify a baseline delta, i.e., acceptable noise ranges, between the two scans. Once the noise ranges have been identified, the unit is left in operation and the system performs scheduled pulses (i.e., scans) to take measurements of the backscatter from the unit.

The system evaluates the measurements by comparing a measurement to the baseline delta. If a measurement is within the operational backscatter baseline delta, as per the two-scan differential, then the measurement is noted, and operation continues uninterrupted and measurements are continued to be taken. If a measurement is outside the operational backscatter baseline delta, then the operation is slowed or stopped, depending on user settings, and an alarm is generated, which indicates the part has failed and may be introducing variance into the machine operation. The system can initiate a new 3D print of the part that failed as soon as the alarm is generated, so that the new 3D printed part can be ready to replace the failed part and repairs can be done quickly. If a repair is done, the system repeats the process starting with completing an initial scan of the new 3D printed object, completing a second scan, identifying a baseline delta, and performing scheduled pulses on the unit in operation to take measurements of the backscatter.

Implementation of embodiments of the invention may take a variety of forms, and exemplary implementation details are discussed subsequently with reference to the Figures.

FIG.1is a functional block diagram illustrating a distributed data processing environment, generally designated100, in accordance with one embodiment of the present invention. In an embodiment, distributed data processing environment100is a degradation notification system for early notification of degradation of 3D printed objects. The term “distributed,” as used herein, describes a computer system that includes multiple, physically distinct devices that operate together as a single computer system.FIG.1provides only an illustration of one implementation and does not imply any limitations with regard to the environments in which different embodiments may be implemented. Many modifications to the depicted environment may be made by those skilled in the art without departing from the scope of the invention as recited by the claims.

Distributed data processing environment100includes server110, 3D printed part120, and user computing device130interconnected over network105. Network105can be, for example, a telecommunications network, a local area network (LAN), a wide area network (WAN), such as the Internet, or a combination of the three, and can include wired, wireless, or fiber optic connections. Network105can include one or more wired and/or wireless networks capable of receiving and transmitting data, voice, and/or video signals, including multimedia signals that include voice, data, and video information. In general, network105can be any combination of connections and protocols that will support communications between server110, 3D printed part120, user computing device130, and other computing devices (not shown) within distributed data processing environment100.

Server110can be a standalone computing device, a management server, a web server, a mobile computing device, or any other electronic device or computing system capable of receiving, sending, and processing data. In other embodiments, server110can represent a server computing system utilizing multiple computers as a server system, such as in a cloud computing environment. In another embodiment, server110can be a laptop computer, a tablet computer, a netbook computer, a personal computer (PC), a desktop computer, a personal digital assistant (PDA), a smart phone, or any programmable electronic device capable of communicating with 3D printed part120, user computing device130, and other computing devices (not shown) within distributed data processing environment100via network105. In another embodiment, server110represents a computing system utilizing clustered computers and components (e.g., database server computers, application server computers, etc.) that act as a single pool of seamless resources when accessed within distributed data processing environment100. Server110includes 3D printed part degradation program112and database114. Server110may include internal and external hardware components, as depicted, and described in further detail with respect toFIG.3.

Degradation notification program112operates for early notification of degradation of 3D printed objects. In the depicted embodiment, degradation notification program112is a standalone program. In another embodiment, degradation notification program112may be integrated into another software product, such as a software package for a 3D printer. Degradation notification program112is depicted and described in further detail with respect toFIG.2.

Database114operates as a repository for data received, used, and/or output by degradation notification program112. Data received, used, and/or generated may include, but is not limited to, backscatter scans and a determined baseline delta; backscatter measurements; alarm settings; data input by users through user computing device130; and any other data received, used, and/or output by degradation notification program112. Database114can be implemented with any type of storage device capable of storing data and configuration files that can be accessed and utilized by server110, such as a hard disk drive, a database server, or a flash memory. In an embodiment, database114is accessed by degradation notification program112to store and/or to access the data. In the depicted embodiment, database114resides on server110. In another embodiment, database114may reside on another computing device, server, cloud server, or spread across multiple devices elsewhere (not shown) within distributed data processing environment100, provided that degradation notification program112has access to database114.

The present invention may contain various accessible data sources, such as database114, that may include personal and/or confidential company data, content, or information the user wishes not to be processed. Processing refers to any operation, automated or unautomated, or set of operations such as collecting, recording, organizing, structuring, storing, adapting, altering, retrieving, consulting, using, disclosing by transmission, dissemination, or otherwise making available, combining, restricting, erasing, or destroying personal and/or confidential company data. Degradation notification program112enables the authorized and secure processing of personal data.

Degradation notification program112provides informed consent, with notice of the collection of personal and/or confidential company data, allowing the user to opt in or opt out of processing personal and/or confidential company data. Consent can take several forms. Opt-in consent can impose on the user to take an affirmative action before personal and/or confidential company data is processed. Alternatively, opt-out consent can impose on the user to take an affirmative action to prevent the processing of personal and/or confidential company data before personal and/or confidential company data is processed. Degradation notification program112provides information regarding personal and/or confidential company data and the nature (e.g., type, scope, purpose, duration, etc.) of the processing. Degradation notification program112provides the user with copies of stored personal and/or confidential company data. Degradation notification program112allows the correction or completion of incorrect or incomplete personal and/or confidential company data. Degradation notification program112allows for the immediate deletion of personal and/or confidential company data.

3D printed part120operates as a part or component of a unit (e.g., mechanical system) that has been 3D printed. The unit may comprise multiple 3D printed parts and the system herein can perform this process for any number of 3D printed parts.

User computing device130operates as a computing device associated with at least one user on which the user can interact with degradation notification program112through an application user interface. In an embodiment, user computing device130is associated with a user who has opted-in to degradation notification program112, such as an operator of the unit. In the depicted embodiment, user computing device130includes an instance of user interface132. In an embodiment, user computing device130can be a laptop computer, a tablet computer, a smart phone, a smart watch, an e-reader, smart glasses, wearable computer, or any programmable electronic device capable of communicating with various components and devices within distributed data processing environment100, via network105. In general, user computing device130represents one or more programmable electronic devices or combination of programmable electronic devices capable of executing machine readable program instructions and communicating with other computing devices (not shown) within distributed data processing environment100via a network, such as network105. User computing device130may include internal and external hardware components, as depicted, and described in further detail with respect toFIG.3.

User interface132provides an interface between degradation notification program112on server110and a user of user computing device130. In one embodiment, user interface132is a mobile application software. Mobile application software, or an “app,” is a computer program designed to run on smart phones, tablet computers, and other mobile computing devices. In one embodiment, user interface132may be a graphical user interface (GUI) or a web user interface (WUI) that can display text, documents, web browser windows, user options, application interfaces, and instructions for operation, and include the information (such as graphic, text, and sound) that a program presents to a user and the control sequences the user employs to control the program. User interface132enable users of user computing device130to opt-in to degradation notification program112and configure user settings. For example, degradation notification program112enables a user to configure alarm settings.

FIG.2is a flowchart200depicting operational steps of degradation notification program112, for early notification of degradation of 3D printed parts, in accordance with an embodiment of the present invention. It should be appreciated that the process depicted inFIG.2illustrates one possible iteration of degradation notification program112.

In step205, degradation notification program112identifies that a 3D printed part has been installed into a unit. In an embodiment, degradation notification program112identifies that a 3D printed part has been installed into a unit, i.e., placed into operation in a system, e.g., a mechanical unit. The 3D printed part is printed using a multi-material print. The print has a metallic filament print engulfed between layers of non-metallic compound as known to a person of skill in the art. The metallic filaments reside engulfed in non-metallic casing, as the exposure of this metallic filament results in a positive antenna feedback, i.e., a one (1) state as described above. At least two layers of thickness is needed between metallic filaments to ensure they are properly isolated from each other and from an external wall of the object. In an embodiment, degradation notification program112reviews a 3D print data file to ensure all of these settings are set and the 3D printed part is completed correctly. Responsive to the 3D printed part being completed, inspected, and placed into operation, degradation notification program112identifies that the 3D printed part has been installed into a unit.

In step210, degradation notification program112completes an initial scan of the 3D printed part as installed and while idle in the unit to identify backscatter. In an embodiment, degradation notification program112completes an initial scan (i.e., takes a backscatter image) of the 3D printed part to identify the backscatter form (i.e., shape) of the part as installed idle in the unit. In an embodiment, degradation notification program112utilize backscatter techniques over WiFi® or Bluetooth® or any other backscatter techniques available to complete the initial scan of the 3D printed part.

In step215, degradation notification program112completes a second scan of the 3D printed part once the unit is in operation to identify backscatter. In an embodiment, degradation notification program112completes a second scan (i.e., takes a backscatter image) of the 3D printed part (or the part within the unit) to identify the backscatter form (i.e., shape) once the unit is in operation. In an embodiment, degradation notification program112utilize backscatter techniques over WiFi® or Bluetooth® or any other backscatter techniques available to complete the second scan of the 3D printed part.

In step220, degradation notification program112determines a baseline delta for backscatter between the two scans. In an embodiment, degradation notification program112determines a baseline delta for backscatter using the initial scan and the second scan of the 3D printed part within the unit, i.e., an acceptable noise range between the two scans or a differential value range between the two scans. After some time, if the 3D printed part shows some tear and wear, the metallic filaments of the 3D printed part will be exposed causing a different reading in contrast with the baseline. Therefore, this baseline delta between backscatter readings is what degradation notification program112uses to determine that there is some defects caused by time, wear, and tear on the 3D printed part.

In step225, degradation notification program112performs scheduled pulses of the unit in operation to measure backscatter. In an embodiment, degradation notification program112performs scheduled pulses (i.e., preset scans) of the 3D printed part in operation within the unit. In an embodiment, degradation notification program112performs the scans using the same backscatter techniques to identify any deltas (i.e., changes) which may indicate a defect in the 3D printed part.

In decision230, degradation notification program112determines whether a measurement taken is within the baseline delta. In an embodiment, degradation notification program112determines whether a measurement taken is within the baseline delta by comparing the measurement to the baseline delta.

If degradation notification program112determines the measurement taken is within the baseline delta, degradation notification program112proceed to step235, in which degradation notification program112stores the measurement, allows operation to continue uninterrupted, and continues to perform scheduled pulses (returning to step225).

If degradation notification program112determines the measurement taken is not within the baseline delta, degradation notification program112proceeds to step240, in which degradation notification program112(1) generates an alarm to notify a user that the 3D printed part has failed and may be introducing variance into the operation and (2) slows or stops the operation of the unit, depending on user settings. In an embodiment, degradation notification program112outputs an alarm to a user through a user interface of a user computing device notifying the user that the 3D printed part has failed in some way.

In step245, degradation notification program112initiates 3D printing of a new part to replace the failed 3D printed part. In an embodiment, responsive to generating the alarm, degradation notification program112initiates 3D printing of a new part to replace the failed 3D printed part. This ensure a new 3D printed part is ready as soon as possible and repairs can be done quickly.

In step250, degradation notification program112identifies the new part has been installed in the unit and returns to step210to complete an initial scan of the new part and proceed through the steps again, as necessary.

FIG.3depicts a block diagram of components of computing device300, suitable for server110and/or user computing device130within distributed data processing environment100ofFIG.1, in accordance with an embodiment of the present invention. It should be appreciated thatFIG.3provides only an illustration of one implementation and does not imply any limitations with regard to the environments in which different embodiments can be implemented. Many modifications to the depicted environment can be made.

Computing device300includes communications fabric302, which provides communications between cache316, memory306, persistent storage308, communications unit310, and input/output (I/O) interface(s)312. Communications fabric302can be implemented with any architecture designed for passing data and/or control information between processors (such as microprocessors, communications and network processors, etc.), system memory, peripheral devices, and any other hardware components within a system. For example, communications fabric302can be implemented with one or more buses or a crossbar switch.

Memory306and persistent storage308are computer readable storage media. In this embodiment, memory306includes random access memory (RAM). In general, memory306can include any suitable volatile or non-volatile computer readable storage media. Cache316is a fast memory that enhances the performance of computer processor(s)304by holding recently accessed data, and data near accessed data, from memory306.

Programs may be stored in persistent storage308and in memory306for execution and/or access by one or more of the respective computer processors304via cache316. In an embodiment, persistent storage308includes a magnetic hard disk drive. Alternatively, or in addition to a magnetic hard disk drive, persistent storage308can include a solid state hard drive, a semiconductor storage device, read-only memory (ROM), erasable programmable read-only memory (EPROM), flash memory, or any other computer readable storage media that is capable of storing program instructions or digital information.

Communications unit310, in these examples, provides for communications with other data processing systems or devices. In these examples, communications unit310includes one or more network interface cards. Communications unit310may provide communications through the use of either or both physical and wireless communications links. Programs may be downloaded to persistent storage308through communications unit310.

I/O interface(s)312allows for input and output of data with other devices that may be connected to server110and/or user computing device130. For example, I/O interface312may provide a connection to external devices318such as a keyboard, keypad, a touch screen, and/or some other suitable input device. External devices318can also include portable computer readable storage media such as, for example, thumb drives, portable optical or magnetic disks, and memory cards. Software and data used to practice embodiments of the present invention can be stored on such portable computer readable storage media and can be loaded onto persistent storage308via I/O interface(s)312. I/O interface(s)312also connect to a display320.