Patent Description:
Additive manufacturing processes generally involve the buildup of one or more materials to make an object, in contrast to subtractive manufacturing methods, which remove material. Additive manufacturing can be utilized to form a variety of components having both simple and intricate geometries.

<CIT> relates to generation of casting molds by additive manufacturing. <CIT> relates to a method and apparatus of correcting a superfluous curing thickness of an optical modeling product. <CIT> relates to manipulating one or more formation variables to form three-dimensional objects.

In one aspect, the present disclosure relates to a method of printing a component that includes receiving an original model of the component at a printer, identifying an acute angle in a geometry of the original model, compensating the geometry of the original model at the printer to create a compensated model, wherein the compensating includes removing a portion of the original model at the identified acute angle, and printing, with the printer, the component based upon the compensated model such that the printed component is more alike the original model than the compensated model due to distortions of the printer during printing.

Aspects of the present disclosure are described herein in the exemplary context of a turbine engine, which utilizes additive manufacturing to produce molds, components, parts, models, or other aspects of the components of the turbine engine. However, it will be understood that the disclosure is not so limited and has general applicability to environments requiring additive manufacturing, such as those in non-aircraft applications, including other mobile applications and non-mobile industrial, commercial, and residential applications, or any other locale, area, or other environment where additive manufacturing is desirable.

As used herein, the term "additive manufacturing" generally refers to manufacturing processes wherein successive layers of material(s) are provided on each other to "build-up," layer-by-layer, a three-dimensional component. The successive layers generally fuse together to form a monolithic unitary component, which can have a variety of integral sub-components. Monolithic, as used herein, refers to a unitary structure lacking interfaces or joints by virtue of the materials of each layer fusing to or melting with the materials of adjacent layers such that the individual layers lose their identity in the final unitary structure.

Suitable additive manufacturing techniques in accordance with the present disclosure include, for example, Directed Energy Deposition (DED), Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), 3D printing such as by inkjets and laserjets, Sterolithography (SLA), Direct Selective Laser Sintering (DSLS), Electron Beam Sintering (EBS), Electron Beam Melting (EBM), Laser Engineered Net Shaping (LENS), Laser Net Shape Manufacturing (LNSM), Direct Metal Deposition (DMD), Digital Light Processing (DLP), Direct Selective Laser Melting (DSLM), Selective Laser Melting (SLM), Direct Metal Laser Melting (DMI,M), and other known processes.

In addition to using a direct metal laser sintering (DMLS) or direct metal laser melting (DMI,M) process where an energy source is used to selectively sinter or melt portions of a layer of powder, it should be appreciated that according to alternative aspects of the present disclosure, the additive manufacturing process can be a "binder jetting" process. In this regard, binder jetting involves successively depositing layers of additive powder in a similar manner as described above. However, instead of using an energy source to generate an energy beam to selectively melt or fuse the additive powders, binder jetting involves selectively depositing a liquid binding agent onto each layer of powder. The liquid binding agent can be, for example, a photo-curable polymer or another liquid bonding agent. Other suitable additive manufacturing methods and variants are intended to be within the scope of the present subject matter.

In addition, one skilled in the art will appreciate that a variety of materials and methods for bonding those materials can be used and are contemplated as within the scope of the present disclosure. As used herein, references to "fusing" can refer to any suitable process for creating a bonded layer of any of the above materials. For example, if an object is made from polymer, fusing can refer to creating a thermoset bond between polymer materials. If the object is epoxy, the bond can be formed by a crosslinking process. If the material is ceramic, the bond can be formed by a sintering process. If the material is powdered metal, the bond can be formed by a melting or sintering process. One skilled in the art will appreciate that other methods of fusing materials to make a component by additive manufacturing are possible, and the presently disclosed subject matter can be practiced with those methods.

In addition, the additive manufacturing process disclosed herein allows a single component to be formed from multiple materials. Thus, the components described herein can be formed from any suitable mixtures of the above materials. For example, a component can include multiple layers, segments, or parts that are formed using different materials, processes, or on different additive manufacturing machines. In this manner, components can be constructed which have different materials and material properties for meeting the demands of any particular application. In addition, although the components described herein are constructed entirely by additive manufacturing processes, it should be appreciated that in additional aspects of the present disclosure, all or a portion of these components can be formed via casting, machining, or any other suitable manufacturing process. Indeed, any suitable combination of materials and manufacturing methods can be used to form these components.

An exemplary additive manufacturing process will now be described. Additive manufacturing processes fabricate components using three-dimensional (3D) information, for example a three-dimensional computer model, of the component. Accordingly, a three-dimensional design model of the component can be defined prior to manufacturing. In this regard, a model or prototype of the component can be scanned to determine the three-dimensional information of the component. As another example, a model of the component can be constructed using a suitable computer aided design (CAD) program to define the three-dimensional design model of the component.

The design model can include 3D numeric coordinates of the entire configuration of the component including both external and internal surfaces of the component. For example, the design model can define the body, the surface, and/or internal passageways such as passageways, voids, support structures, etc. In one exemplary non-limiting example, the three-dimensional design model is converted into a plurality of slices or segments, e.g., along a central (e.g., vertical) axis of the component or any other suitable axis. Each slice can define a thin cross section of the component for a predetermined height of the slice. The plurality of successive cross-sectional slices together form the 3D component. The component is then "built-up" sliceby-slice, or layer-by-layer, until finished.

In this manner, the components described herein can be fabricated using the additive process, or more specifically each layer is successively formed, e.g., by fusing or polymerizing a plastic using laser energy or heat or by sintering or melting metal powder. For example, a particular type of additive manufacturing process can use an energy beam, for example, an electron beam or electromagnetic radiation such as a laser beam, to sinter or melt a powder material. Any suitable laser and laser parameters can be used, including considerations with respect to power, laser beam spot size, and scanning velocity. The build material can be formed by any suitable powder or material selected for enhanced strength, durability, and useful life, particularly at high temperatures.

Each successive layer can be, for example, between about <NUM> micrometers (µm) and <NUM>, although the thickness can be selected based on any number of parameters and can be any suitable size according to alternative aspects of the present disclosure. Therefore, utilizing the additive formation methods described above, the components described herein can have cross sections as thin as one thickness of an associated powder layer, e.g., <NUM>, utilized during the additive formation process.

In addition, utilizing an additive process, the surface finish and features of the components can vary as need depending on the application. For example, the surface finish can be adjusted (e.g., made smoother or rougher) by selecting appropriate laser scan parameters (e.g., laser power, scan speed, laser focal spot size, etc.) during the additive process, especially in the periphery of a cross-sectional layer, which corresponds to the part surface. For example, a rougher finish can be achieved by increasing laser scan speed or decreasing the size of the melt pool formed, and a smoother finish can be achieved by decreasing laser scan speed or increasing the size of the melt pool formed. The scanning pattern or laser power can also be changed to change the surface finish in a selected area.

Notably, in exemplary non-limiting examples, several features of the components described herein were previously not possible due to manufacturing restraints. However, the present inventors have advantageously utilized current advances in additive manufacturing techniques to develop such components generally in accordance with the present disclosure. While the present disclosure is not limited to the use of additive manufacturing to form these components generally, additive manufacturing does provide a variety of manufacturing advantages, including ease of manufacturing, reduced cost, greater accuracy, etc..

As used herein, the term "upstream" refers to a direction that is opposite the fluid flow direction, and the term "downstream" refers to a direction that is in the same direction as the fluid flow. The term "fore" or "forward" means in front of something and "aft" or "rearward" means behind something. For example, when used in terms of fluid flow, fore/forward can mean upstream and aft/rearward can mean downstream.

Additionally, as used herein, the terms "radial" or "radially" refer to a direction away from a common center. For example, in the overall context of a turbine engine, radial refers to a direction along a ray extending between a center longitudinal axis of the engine and an outer engine circumference. Furthermore, as used herein, the term "set" or a "set" of elements can be any number of elements, including only one.

Additionally, as used herein, a "controller" or "controller module" can include a component configured or adapted to provide instruction, control, operation, or any form of communication for operable components to affect the operation thereof. A controller module can include any known processor, microcontroller, or logic device, including, but not limited to: field programmable gate arrays (FPGA), an application specific integrated circuit (ASIC), a full authority digital engine control (FADEC), a proportional controller (P), a proportional integral controller (PI), a proportional derivative controller (PD), a proportional integral derivative controller (PID controller), a hardware-accelerated logic controller (e.g. for encoding, decoding, transcoding, etc.), the like, or a combination thereof. Non-limiting examples of a controller module can be configured or adapted to run, operate, or otherwise execute program code to effect operational or functional outcomes, including carrying out various methods, functionality, processing tasks, calculations, comparisons, sensing or measuring of values, or the like, to enable or achieve the technical operations or operations described herein. The operation or functional outcomes can be based on one or more inputs, stored data values, sensed or measured values, true or false indications, or the like. While "program code" is described, non-limiting examples of operable or executable instruction sets can include routines, programs, objects, components, data structures, algorithms, etc., that have the technical effect of performing particular tasks or implement particular abstract data types. In another non-limiting example, a controller module can also include a data storage component accessible by the processor, including memory, whether transient, volatile or non-transient, or non-volatile memory. Additional non-limiting examples of the memory can include Random Access Memory (RAM), Read-Only Memory (ROM), flash memory, or one or more different types of portable electronic memory, such as discs, DVDs, CD-ROMs, flash drives, universal serial bus (USB) drives, the like, or any suitable combination of these types of memory. In one example, the program code can be stored within the memory in a machine-readable format accessible by the processor. Additionally, the memory can store various data, data types, sensed or measured data values, inputs, generated or processed data, or the like, accessible by the processor in providing instruction, control, or operation to affect a functional or operable outcome, as described herein.

Additionally, as used herein, elements being "electrically connected," "electrically coupled," "communicatively coupled" or "in electrical communication", as well as terminology similar thereto, can include an electric, wired or wireless, transmission or signal being sent, received, or communicated to or from such connected or coupled elements. Furthermore, such electrical connections or couplings can include a wired or wireless connection, or a combination thereof.

Also, as used herein, while sensors can be described as "sensing" or "measuring" a respective value, sensing or measuring can include determining a value indicative of or related to the respective value, rather than directly sensing or measuring the value itself. The sensed or measured values can further be provided to additional components. For instance, the value can be provided to a controller module or processor as defined above, and the controller module or processor can perform processing on the value to determine a representative value or an electrical characteristic representative of said value.

All directional references (e.g., radial, axial, proximal, distal, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, forward, aft, etc.) are used only for identification purposes to aid the reader's understanding of the present disclosure, and should not be construed as limiting on an example, particularly as to the position, orientation, or use of aspects of the disclosure described herein. Connection references (e.g., attached, coupled, connected, and joined) are to be construed broadly and can include intermediate members between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to one another. The exemplary drawings are for purposes of illustration only and the dimensions, positions, order and relative sizes reflected in the drawings attached hereto can vary.

<FIG> is a schematic cross-sectional diagram of a turbine engine <NUM> for an aircraft. The turbine engine <NUM> has a centerline or longitudinal axis <NUM> extending forward <NUM> to aft <NUM>. The turbine engine <NUM> includes, in downstream serial flow relationship, a fan section <NUM> including a fan <NUM>, a compressor section <NUM> including a booster or low pressure (LP) compressor <NUM> and a high pressure (HP) compressor <NUM>, a combustion section <NUM> including a combustor <NUM>, a turbine section <NUM> including a HP turbine <NUM>, and a LP turbine <NUM>, and an exhaust section <NUM>.

The fan section <NUM> includes a fan casing <NUM> surrounding the fan <NUM>. The fan <NUM> includes a plurality of fan blades <NUM> disposed radially about the longitudinal axis <NUM>. The HP compressor <NUM>, the combustor <NUM>, and the HP turbine <NUM> form an engine core <NUM>, which generates combustion gases. The engine core <NUM> is surrounded by core casing <NUM>, which can be coupled with the fan casing <NUM>.

A HP shaft or spool <NUM> disposed coaxially about the longitudinal axis <NUM> of the turbine engine <NUM> drivingly connects the HP turbine <NUM> to the HP compressor <NUM>. A LP shaft or spool <NUM>, which is disposed coaxially about the longitudinal axis <NUM> of the turbine engine <NUM> within the larger diameter annular HP spool <NUM>, drivingly connects the LP turbine <NUM> to the LP compressor <NUM> and fan <NUM>. The spools <NUM>, <NUM> are rotatable about the engine centerline and couple to a plurality of rotatable elements, which can collectively define an inner rotor/stator <NUM>. While illustrated as a rotor, it is contemplated that the inner rotor/stator <NUM> can be a stator.

The LP compressor <NUM> and the HP compressor <NUM> respectively include a plurality of compressor stages <NUM>, <NUM>, in which a set of compressor blades <NUM>, <NUM> rotate relative to a corresponding set of static compressor vanes <NUM>, <NUM> (also called a nozzle) to compress or pressurize the stream of fluid passing through the stage. In a single compressor stage <NUM>, <NUM>, multiple compressor blades <NUM>, <NUM> can be provided in a ring and can extend radially outwardly relative to the longitudinal axis <NUM>, from a blade platform to a blade tip, while the corresponding static compressor vanes <NUM>, <NUM> are positioned upstream of and adjacent to the rotating compressor blades <NUM>, <NUM>. It is noted that the number of blades, vanes, and compressor stages shown in <FIG> were selected for illustrative purposes only, and that other numbers are possible.

The compressor blades <NUM>, <NUM> for a stage of the compressor can be mounted to a disk <NUM>, which is mounted to the corresponding one of the HP and LP spools <NUM>, <NUM>, with each stage having its own disk <NUM>. The vanes <NUM>, <NUM> for a stage of the compressor can be mounted to the core casing <NUM> in a circumferential arrangement.

The HP turbine <NUM> and the LP turbine <NUM> respectively include a plurality of turbine stages <NUM>, <NUM>, in which a set of turbine blades <NUM>, <NUM> are rotated relative to a corresponding set of static turbine vanes <NUM>, <NUM> (also called a nozzle) to extract energy from the stream of fluid passing through the stage. In a single turbine stage <NUM>, <NUM>, multiple turbine blades <NUM>, <NUM> can be provided in a ring and can extend radially outwardly relative to the longitudinal axis <NUM>, from a blade platform to a blade tip, while the corresponding static turbine vanes <NUM>, <NUM> are positioned upstream of and adjacent to the rotating blades <NUM>, <NUM>. It is noted that the number of blades, vanes, and turbine stages shown in <FIG> were selected for illustrative purposes only, and that other numbers are possible.

The blades <NUM>, <NUM> for a stage of the turbine can be mounted to a disk <NUM>, which is mounted to the corresponding one of the HP and LP spools <NUM>, <NUM>, with each stage having a dedicated disk <NUM>. The vanes <NUM>, <NUM> for a stage of the compressor can be mounted to the core casing <NUM> in a circumferential arrangement.

Complementary to the rotor portion, the stationary portions of the turbine engine <NUM>, such as the static vanes <NUM>, <NUM>, <NUM>, <NUM> among the compressor and turbine section <NUM>, <NUM> are also referred to individually or collectively as an outer rotor/stator <NUM>. As illustrated, the outer rotor/stator <NUM> can refer to the combination of non-rotating elements throughout the turbine engine <NUM>. Alternatively, the outer rotor/stator <NUM> that circumscribes at least a portion of the inner rotor/stator <NUM>, can be designed to rotate. The inner or outer rotor/stator <NUM>, <NUM> can include at least one component that can be, by way of non-limiting example, a shroud, vane, nozzle, nozzle body, combustor, hanger, or blade, where the at least one component is a plurality of circumferentially arranged component segments having confronting pairs of circumferential ends.

In operation, the airflow exiting the fan section <NUM> is split such that a portion of the airflow is channeled into the LP compressor <NUM>, which then supplies pressurized airflow <NUM> to the HP compressor <NUM>, which further pressurizes the air. The pressurized airflow <NUM> from the HP compressor <NUM> is mixed with fuel in the combustor <NUM> and ignited, thereby generating combustion gases. Some work is extracted from these gases by the HP turbine <NUM>, which drives the HP compressor <NUM>. The combustion gases are discharged into the LP turbine <NUM>, which extracts additional work to drive the LP compressor <NUM>, and the exhaust gas is ultimately discharged from the turbine engine <NUM> via the exhaust section <NUM>. The driving of the LP turbine <NUM> drives the LP spool <NUM> to rotate the fan <NUM> and the LP compressor <NUM>.

A portion of the pressurized airflow <NUM> can be drawn from the compressor section <NUM> as bleed air <NUM>. The bleed air <NUM> can be drawn from the pressurized airflow <NUM> and provided to engine components requiring cooling. The temperature of pressurized airflow <NUM> entering the combustor <NUM> is significantly increased. As such, cooling provided by the bleed air <NUM> is necessary for operating such engine components in the heightened temperature environments.

A remaining portion of the airflow <NUM> bypasses the LP compressor <NUM> and the engine core <NUM> and exits the turbine engine <NUM> through a stationary vane row, and more particularly an outlet guide vane assembly <NUM>, comprising a plurality of airfoil guide vanes <NUM>, at the fan exhaust side <NUM>. More specifically, a circumferential row of radially extending airfoil guide vanes <NUM> are utilized adjacent the fan section <NUM> to exert some directional control of the airflow <NUM>.

Some of the air supplied by the fan <NUM> can bypass the engine core <NUM> and be used for cooling of portions, especially hot portions, of the turbine engine <NUM>, and/or used to cool or power other aspects of the aircraft. In the context of a turbine engine, the hot portions of the engine are normally downstream of the combustor <NUM>, especially the turbine section <NUM>, with the HP turbine <NUM> being the hottest portion as it is directly downstream of the combustion section <NUM>. Other sources of cooling fluid can be, but are not limited to, fluid discharged from the LP compressor <NUM> or the HP compressor <NUM>.

<FIG> is a schematic illustrating of an additive manufacturing device for producing a portion of or component for the turbine engine of <FIG>. While the additive manufacturing as described herein is discussed in relation to a turbine engine, component therefore, or portion thereof, it should be appreciated that the parts, components, or elements printed by the additive manufacturing device can be for any implementation or application, such as those outside of a turbine engine, including but not limited to residential, non-residential, commercial, industrial, or any other application. The additive manufacturing device is illustrated, by way of non-limiting example, as a digital light processing (DLP) 3D printer <NUM>. The DLP 3D printer <NUM> can include a transparent vat or transparent tank <NUM> containing, for example, a photopolymer resin <NUM>. A building platform <NUM> couples to a motor <NUM> permitting movement in the direction of at least the Z-axis <NUM>, such as for raising or lowering the building platform <NUM> from or toward the resin <NUM>. A printed part, component, or final model <NUM> couples to a lower portion <NUM> of the building platform <NUM>.

A lighting assembly <NUM> is located, at least in part, below the tank <NUM>. The lighting assembly <NUM> can include a light source <NUM>, a deflection mirror <NUM>, and at least one lens <NUM>. A controller <NUM> can couple to or be in communication with the light source <NUM> and the motor <NUM>. The controller <NUM> can include a memory <NUM> for programming software or operational software, as well as a processor <NUM> for performing tasks or running the software, for example.

In operation, an original model <NUM> is loaded into the controller <NUM> or recalled from the memory <NUM>. The original model <NUM> can be stored or virtually created as a virtual model. The term "virtual model" as used herein relates to a digital representation of a physical object and serves as a basis for simulating the fabrication process of the object. The virtual model can also be used to prototype the object.

The controller <NUM> processes the original model <NUM> into a plurality of layers. The layers can be arranged into reverse layers in the Z-axis direction, such that the component is built from the bottom up. The controller <NUM> then moves the building platform <NUM> into the photopolymer resin <NUM>, until a predetermined distance between the lower portion <NUM> and a base of the tank <NUM> is achieved.

The controller <NUM> activates the light source <NUM>. The light, illustrated as rays <NUM>, can be a beam of light that is guided to the tank <NUM> via the deflection mirror <NUM> and the lens <NUM>. The controller <NUM> can adjust the light source <NUM>, the number of rays <NUM>, the intensity of the rays <NUM>, the deflection mirror <NUM>, or the lens <NUM> so that a layer of resin based on the first required layer of the original model <NUM> is cured by the light rays <NUM> and affixed to the lower portion <NUM> of the building platform <NUM>. The layer of resin can include inconsistencies from the first required layer of the original model <NUM> due to distortions during printing.

The controller <NUM> then raises the building platform <NUM> a predetermined distance, which can be the width of one build layer, for example. Again, the light source <NUM>, the deflection mirror <NUM>, or the lens <NUM> are adjusted so that a layer of resin based on the second required layer of the original model <NUM> is cured to the first required layer on the lower portion <NUM> of the building platform <NUM>.

This process repeats until the final model <NUM> is complete. The final model <NUM> often does not include all the detail or features of the original model <NUM> due to distortions during forming. By way of non-limiting example, the final model <NUM> can include curved portions <NUM>, which often occur when sharp acute angles <NUM> are included in the geometry of the original model <NUM>. In <FIG>, such a distortion is identifiable, as the acute angles <NUM> in the original model <NUM> are printed as the curved portions <NUM> in the final model <NUM>.

<FIG> illustrate, by way of non-limiting example, a compensation for the original model, such as an electronic compensation that results in the final model <NUM> more closely matching the dimensions, shape, and angles of the original model <NUM>, minimizing, reducing, or eliminating the distortions resultant of the printing or forming technique.

<FIG> illustrates a cross sectional view of the original model <NUM> with first and second walls <NUM>, <NUM> coupled by a ligament <NUM>. The intersection of the ligament <NUM> with the first and/or second walls <NUM>, <NUM> can define first and/or second acute angles 130a, 130b. It should be appreciated that the models described herein, such as the original model <NUM>, can be virtual or computer-generated models, such as formed on a computer, a computer program or other software, or any other medium or platform that does not require a physical embodiment of the model, while a physical manifestation is contemplated.

The first acute angle 130a can be measured from a first inner platform <NUM> of the first wall <NUM> to a first outside edge <NUM> of the ligament <NUM> adjacent the first inner platform <NUM>. The second acute angle 130b can be measured from a second inner platform <NUM> of the second wall <NUM> to a second outside edge <NUM> of the ligament <NUM> adjacent the second inner platform <NUM>. The first and second acute angles 130a, 130b can be any acute angle or right angle between and including <NUM> degrees to <NUM> degrees. While illustrated as having relatively the same measurement, it is contemplated that the first acute angle 130a can be greater than, less than, or equal to the second acute angle 130b. It is further contemplated that the first wall <NUM>, the second wall <NUM>, or ligament can have any shape, contour, or orientation. The inset distance of the first or second acute angle 130a, 130b is essentially zero, as the angle is measured from the first or second inner platforms <NUM>, <NUM> that do not include inset walls or portions. The term "inset distance" can be the maximum distance a negative print region extends into a wall, as measured from the inner platform.

<FIG> illustrates a cross sectional view of a compensated model <NUM> that can be a virtual or computer-generated model, in one non-limiting example, similar to that of the original model <NUM> of <FIG>. The compensated model <NUM> can be defined as the original model <NUM> including at least one compensation. The at least one compensation can be a negative print region, where the shape of the negative print region includes intentional and predetermined geometries. As illustrated, by way of non-limiting example, the compensation can be first and second negative print regions <NUM>, <NUM> in the shape of triangles, while any suitable geometry is contemplated. As used herein, the term "negative print region" relates to a region where material is removed from the original model. That is, regions of the original model <NUM> denoted as printable material that are intentionally not included to be printable material in the compensated model <NUM>. The first and second negative print regions <NUM>, <NUM> remove portions of the first and second walls <NUM>, <NUM> that partially form the first and second acute angles 130a, 130b.

The first negative print region <NUM> can, at least in part, be defined by a first set of inset walls <NUM> that are portions of the first inner platform <NUM> that extend into the first wall <NUM> a maximum of a first inset distance <NUM>. A first acute angle <NUM> can be defined by at least one of the first set of inset walls <NUM> adjacent the first outside edge <NUM> of the ligament <NUM>.

The second negative print region <NUM> can, at least in part, be defined by a second set of inset walls <NUM> that are portions of the second inner platform <NUM> that extend into the second wall <NUM> a maximum of a second inset distance <NUM>. A second acute angle <NUM> can be defined by at least one of the second set of inset walls <NUM> adjacent the second outside edge <NUM> of the ligament <NUM>.

<FIG> illustrates a cross sectional view of the final model <NUM> printed by an additive manufacturing device based on the compensation model <NUM>. The final model <NUM> includes first and second printed walls <NUM>, <NUM> coupled by a printed ligament <NUM>. The intersection of the printed ligament <NUM> and the first and second printed walls <NUM>, <NUM> can define first and second acute angles <NUM>, <NUM>.

The first acute angle <NUM> can be defined as the angle between at least one of a first set of inset walls <NUM> and a first outside edge <NUM> of the printed ligament <NUM> adjacent to the at least one of the first set of inset walls <NUM>. The first set of inset walls <NUM> are portions of a first inner platform <NUM> that extend into the first printed wall <NUM> to a first inset distance <NUM>.

The second acute angle <NUM> can be defined as the angle between at least one of a second set of inset walls <NUM> and a second outside edge <NUM> of the printed ligament <NUM> adjacent to the at least one of the second set of inset walls <NUM>. The second set of inset walls <NUM> are portions of a second inner platform <NUM> that extend into the second printed wall <NUM> to a second inset distance <NUM>.

In operation, <FIG> illustrates the desired component to be printed as the original model <NUM>. The compensated model <NUM> uses the original model <NUM> and compensates for distortions during the forming of the component. The compensation for distortions can include the input of the original model into one or more software programs for analysis. The analysis can include the detection or identification of geometries likely to result in distortions. The compensated model <NUM> results from predetermined compensations based on the geometries likely to result in distortions in order to minimize distortions.

The compensation illustrated in <FIG> is an example of compensation for sharp acute angles that, when printed, can result in curved portions <NUM> (<FIG>). The compensation can include the first and second negative print regions <NUM>, <NUM>, modifying the original model <NUM>, so that when the compensation model <NUM> is used to form the component, the result, as shown in <FIG>, is that the final model <NUM> of the component is more alike the original model than the compensated model <NUM>, or more alike the original model than a printed version without compensation, or both. More specifically, the determination of "more alike" can be the comparison of dimension values of similar aspects of the original model <NUM>, the compensated model <NUM>, and the final model <NUM>. By way of non-limiting example, the final model <NUM> is more alike the original model <NUM> when the first acute angle <NUM> of the final model <NUM> is closer in value to the first acute angle 130a of the original model <NUM> than the value of the first acute angle <NUM> of the compensated model <NUM>. Another non-limiting illustration of the final model <NUM> being more alike the original model <NUM> than the compensated model <NUM> is when the second acute angle <NUM> of the final model <NUM> is closer in value to the second acute angle 130b of the original model <NUM> than the value of the first acute angle <NUM> of the compensated model <NUM>. Yet another non-limiting illustration of the final model <NUM> being more alike the original model <NUM> than the compensated model <NUM> is when the first or second inset distance <NUM>, <NUM> of the final model <NUM> is closer in value to the first or second inset distance of the original model <NUM>, illustrated as zero, than the value of the first or second inset distance <NUM>, <NUM> of the compensated model <NUM>.

<FIG> is another example of a compensated model <NUM> that can be used in manufacturing components of the turbine engine <NUM> or other additively manufactured components. The compensated model <NUM> of <FIG> is similar to compensated model <NUM> of <FIG>, therefore, like parts will be identified with like numerals increased by <NUM>, with it being understood that the description of the like parts of the compensated model <NUM> applies to the compensated model <NUM>, unless otherwise noted.

The compensated model <NUM> includes an original model <NUM> and at least one compensation. As illustrated, by way of non-limiting example, the compensation can be a first negative print region <NUM> having a shape that combines a quadrilateral <NUM> and a triangle <NUM>. Further, for example, the second negative print region <NUM> can have a shape that combines a first and second triangle <NUM>, <NUM>. That is, a portion of first and second walls <NUM>, <NUM> originally intended to be printed are removed to form the compensation model <NUM>. The portion of first and second walls <NUM>, <NUM> that is removed partially form first and second compensation angles <NUM>, <NUM>.

The first negative print region <NUM> can, at least in part, be defined by a first set of inset walls <NUM> that are portions of a first inner platform <NUM>. The first set of inset walls <NUM> can extend into the first wall <NUM> a maximum of a first inset distance <NUM>. The first compensation angle <NUM> can be defined by at least one of the first set of inset walls <NUM> adjacent a first outside edge <NUM> of a ligament <NUM>.

The second negative print region <NUM> can, at least in part, be defined by a second set of inset walls <NUM> that are portions of a second inner platform <NUM>. The second set of inset walls <NUM> can extend into the second wall <NUM> a maximum of a second inset distance <NUM>. A second compensation angle <NUM> can be defined by at least one of the second set of inset walls <NUM> adjacent a second outside edge <NUM> of the ligament <NUM>.

<FIG> is yet another example of a compensated model <NUM> that can be used in manufacturing components of the turbine engine <NUM>. The compensated model <NUM> of <FIG> is similar to compensated model <NUM> of <FIG>, and therefore, like parts will be identified with like numerals increased by <NUM>, with it being understood that the description of the like parts of the compensated model <NUM> applies to the compensated model <NUM>, unless otherwise noted.

The compensated model <NUM> includes an original model <NUM> and at least one compensation. As illustrated, by way of non-limiting example, the compensation can be a first and second negative print region <NUM>, <NUM> in the shape of triangles <NUM>, <NUM>. The first and second negative print region <NUM>, <NUM> remove a portion of first and second walls <NUM>, <NUM> that partially form first and second angles <NUM>, <NUM>.

The first negative print region <NUM> can, at least in part, be defined by a first set of inset walls <NUM> that are portions of a first inner platform <NUM>. The first set of inset walls <NUM> can extend into the first wall <NUM> a maximum of a first inset distance <NUM>. The first angle <NUM> can be defined by at least one of the first set of inset walls <NUM> adjacent a first outside edge <NUM> of a ligament <NUM>.

The second negative print region <NUM> can, at least in part, be defined by a second set of inset walls <NUM> that are portions of a second inner platform <NUM>. The second set of inset walls <NUM> can extend into the second wall <NUM> a maximum of a second inset distance <NUM>. The second angle <NUM> can be defined by at least one of the second set of inset walls <NUM> adjacent a second outside edge <NUM> of the ligament <NUM>.

<FIG> are non-limiting examples of compensation models. Compensation models can include any number of negative print regions when compared to the original model. It is contemplated that the negative print regions can actually be positive print regions where material is added to the print design of the compensated model when compared to the original model. Compensations illustrated herein are illustrated by way of cross-section. It is contemplated that compensations can be three dimensional (3D). That is, when the cross section of the component is taken, it can vary, compensating for geometries three dimensionally. For example, the three-dimensional geometries can include shapes or portions thereof that are geometric, linear, curved, curvilinear, unique, angled, or any combination thereof, in non-limiting examples. More specifically, it should be understood that a variety of geometries can result in distortions of the final model, and that a variety of compensations can be utilized to minimize or eliminate the distortions, based upon the particular geometry of the final model. For example, the compensated model can include any number of positive or negative print regions. The positive or negative print regions can be shaped as triangles, rectangles, squares, regular or irregular polygon, circles, ovals, or some combination therein, as well as three-dimensional versions thereof as applied to the three-dimensional final model.

<FIG> illustrates a system <NUM> for forming or printing a component according to aspects of the present disclosure. The system <NUM> includes at least a source <NUM> in communication with a printer. It is contemplated that the source <NUM> can be any number of computers or communicating controllers capable of displaying, editing, transmitting, or creating the original model <NUM>.

The printer can be any type of device or machine otherwise used to print or otherwise form components. By way of non-limiting example, the printer is illustrated as the DLP 3D printer <NUM> of <FIG>. The source <NUM> can include a source memory <NUM> and a compensation module <NUM>, such as a processor, that includes compensating software or other executables or computer instructions. Additionally, or alternatively, the compensation module <NUM> or a portion of the compensation module <NUM> can be included in the printer <NUM>. That is, the source <NUM> can communicate the original model <NUM>, the compensated model <NUM>, or a partially compensated model to the printer <NUM>. The original model <NUM> can be, by way of non-limiting example, a digitization of an actual part or a virtual model. It is further contemplated that the compensating software can be housed, installed, or loaded on the source <NUM> or the printer <NUM>. That is, the compensating software can come with the source <NUM> or the printer <NUM> when purchased by a user or the compensating software can be installed or loaded on the source <NUM> or the printer <NUM> after the source <NUM> or printer <NUM> has been purchased by a user.

In operation, the source <NUM> of the system <NUM> generates or retrieves from the source memory <NUM> the original model <NUM>. The original model <NUM> is then input into the compensation software of the compensation module <NUM>. The compensation software can be used to automatically identify portions of the geometry that indicate a distortion may occur, or that a compensation is useful or will result in a more-accurate final model. The compensation software identifies an acute angle and can also identify a sharp corner, an obtuse angle, a rounded region, or other geometries that would not immediately appear in the printed part or final model <NUM> as desired if printed from the original model <NUM>. Alternatively, the identification of portions of the geometries of the original model <NUM> that could be compensated can be done, at least in part, manually.

Once identified, the compensating software modifies the identified distortions by compensating the original model <NUM> to become the compensated model <NUM>, such that printing of the component or the final model <NUM> based upon the compensated model <NUM> is more alike the original model <NUM> than the compensated model <NUM>. The compensated model <NUM> can be communicated to the controller <NUM> of the printer <NUM>. Under direction from the controller <NUM>, the component is then formed or printed by the printer <NUM> using the compensated model <NUM> to operate the printer <NUM>, resulting in the final model <NUM> of the component. The component can be, by way of non-limiting example, at least a portion of an engine component for the turbine engine <NUM>, or a print negative for encasing a portion of or an entire engine component for the turbine engine <NUM>, such as for casting an engine component based upon the printed negative mold. The engine components or portions of engine components that can be formed from or casted by the final model <NUM> can include a blade, a vane, a strut, a service tube, a shroud, or a combustion liner in non-limiting examples, or any other engine component.

Alternatively, the original model <NUM> can be communicated to the controller <NUM> of the printer <NUM>. Optionally, the controller <NUM> can include the compensation module <NUM> (or similar compensation software operable similar to that of the compensation module <NUM>) for determining and generating the compensated model <NUM> before printing the component. Further, it is contemplated that the controller <NUM>, the source <NUM>, or any number of data processing devices can include portions of compensating software or the compensation module <NUM>.

It is contemplated that compensating can further include adjusting a heat, light, speed, or other mechanical, electric, thermal, or magnetic property of the printer during the forming process, which can vary depending on the particular printer or method of printing or forming. These non-geometric compensations may not be immediately visible from the cross section of the compensated model <NUM>, but can be included in the compensation model <NUM>.

<FIG> illustrates a method <NUM> of forming the component. At <NUM>, the original model <NUM> of the component is provided. The original model <NUM> can be provided to the system <NUM> by an outside source or recalled and provided to the system <NUM> from the source memory <NUM>. Outside sources can include a 3D scanner, computer or other electronic device capable of communicating, generating, or providing the original model <NUM>, which can be virtual, to the system <NUM>.

At <NUM>, the geometry of the original model <NUM> is compensated to create the compensated model <NUM>. Compensation of the geometry of the original model <NUM> includes identifying portions of the geometry of the original model <NUM> that include an acute angle and can also include identifying a sharp corner, an obtuse angle, a rounded region, or other geometries resulting in or likely to result in a distortion. That is, the compensation software of the compensation module <NUM> can identify any geometries of the original model <NUM> that would appear varied or in some way distorted in the printed part or final model <NUM> if printed from the original model <NUM>. That is, the compensation software reviews the geometry of the original model <NUM> for geometries that will be significantly distorted during forming or printing. Compensation to the geometry are made based on the knowledge or understanding of how the printer <NUM> can distort select geometries of the original model <NUM> during forming or printing. It should be noted that the particular printer or method of printing may vary the distortions relative to other printers or methods, and therefore, it is contemplated that the type of printer used, as well as other information such as material, temperatures, speed, or otherwise can be provided during compensation to be considered when developing the compensated model <NUM>. By way of non-limiting example, for the first acute angle 130a, material is removed from the first wall <NUM> forming the first acute angle 130a. The material removed can be the first negative print region <NUM> determined, in part, by knowing that curing or forming material at such an angle would normally result in curved portions <NUM> without compensation due to distortions during curing or forming.

At <NUM>, the component is formed based upon the compensated model <NUM> such that the final model <NUM> of the component is more alike the original model <NUM> than the compensated model <NUM> by minimizing, reducing, or eliminating distortions during forming of the component. By way of non-limiting example, the printer <NUM> forms the component using DLP. While illustrated the printer <NUM> is illustrated as a DLP printer, it is contemplated that the printer <NUM> can be any <NUM>-D additive manufacturing printer. It is further considered that the printer <NUM> can be used in photopolymerization based additive manufacturing. Photopolymerization based additive manufacturing is a process by which the final model <NUM> is formed in a layer by layer fashion using photochemical processes by which light causes chemical monomers to link together to form polymers. Non-limiting examples of related technologies that can be used for photopolymerization based additive manufacturing include, but are not limited to continuous liquid interface production (CLIP), daylight polymer printing (DPP), digital light processing (DLP), or stereolithography (SL).

The printer <NUM> can include compensating by modifying the intensity of a light source used in DLP. The compensated model <NUM> can also include compensating information that modifies the intensity of the light source <NUM> used in the printer <NUM>. The intensity of the light source <NUM> can be modified discretely at areas of the original model <NUM>, such as, for example in the regions at the first acute angle <NUM>.

Optionally, the method <NUM> can further include testing the formation of the final model <NUM> based on the compensated model <NUM> to determine if the final model <NUM> will be more alike the original model <NUM> than the compensated model <NUM>. The testing can be done virtually, for example, by a three-dimensional scanner measuring the final model <NUM>, or by virtually generating the final model <NUM> based upon the compensated model <NUM> and utilizing the compensation software to determine what the modified final model <NUM> will be. The scanner, printer <NUM>, or source <NUM> can compare the tested final model <NUM> to the original model <NUM> and update the compensated model <NUM> based upon the testing of formation from the final model <NUM> formed based the compensation model <NUM>. That is, the final model <NUM> is tested via measuring, scanning, or otherwise compared to the original model <NUM> and the compensation software of the compensation module <NUM> is then updated based on the comparison.

<FIG> illustrates a method <NUM> of printing the component. At <NUM>, the original model <NUM> of the component is received at the printer <NUM>. By way of non-limiting example, the controller <NUM> can receive the original model <NUM> or retrieve the original model <NUM> from the memory <NUM> of the printer <NUM>. The original model <NUM> can be provided to the compensation module <NUM> that can be in communication or contained within the printer <NUM>.

At <NUM>, the geometry of the original model <NUM> is then compensated at the printer <NUM> to create the compensated model <NUM>. The compensating can be done by a software program that is on the printer <NUM> or loaded on the printer <NUM>, for example. By way of non-limiting example, using the compensation software used to create the compensated model <NUM> can be the compensation software included in the compensation module <NUM>, where the compensation module <NUM> is housed in or loaded onto the controller <NUM> of the printer <NUM>.

At <NUM>, the printer <NUM> prints the component based upon the compensated model <NUM> such that the printed component, identified by way of non-limiting example as the final model <NUM>, is more alike the original model <NUM> than the compensated model <NUM> due to distortions of the printer <NUM> during printing.

Optionally, the method <NUM> can further include at least one test printing of the compensated model <NUM>. Test printing can include printing the component based on the compensated model <NUM> and determining if the printed component will be more alike the original model <NUM> then the compensated model <NUM>. It is further contemplated that the method <NUM> can optionally include modifying the compensated model <NUM> based upon the test printing, in order to further minimize or eliminate distortions. Additionally, it is contemplated that such test printing can be saved or stored in a system memory, and can be used to update the compensation software based upon the returned test printing data.

The determination can include a three-dimensional scanner or other device or system that can obtain a virtual image of the final model <NUM>, that is, the physically printed component. The compensation module <NUM> or other process or software contained in the printer <NUM> or the source <NUM> can compare the virtual image of the final model <NUM> to virtual image of the original model <NUM> and the virtual image of the compensated model <NUM>. The compensation module <NUM> or other process or software can compare angles, lengths, depths, contour, or any other aspect of the virtual image of the final model <NUM> to the corresponding portions of the virtual image of the original model <NUM> and the virtual image of the compensated model <NUM>. Alternatively, the determination of alike can be done through manual measurement.

If the formation of the final model <NUM> based on the compensated model <NUM> is determined to be more alike the compensated model <NUM> than the original model <NUM>, modifications to the compensated model <NUM> are made based on the alikeness. It is contemplated that the determining of alike can include pre-determined tolerances for differences in measurement of the angles, lengths, depths, contour, or any other aspect of the virtual image of the final model <NUM> and the corresponding portions of the virtual image of the original model <NUM>. By way of non-limiting example, if the percent difference between the first acute angle 130a of the original model <NUM> and the first acute angle <NUM> of the final model <NUM> is greater than <NUM>%, modifications to the compensated model <NUM> are made.

Benefits of aspects of the disclosure can improve the precision of the final printed/formed component from any 3D printer or forming device where the original model includes geometries distorted during the printing/forming process.

Another benefit of using the compensated model is that it allows for parts to be printed/formed that traditionally are not printed/formed due to their geometries.

Yet another benefit of using the compensated model is to produce final geometry that has sharp, detailed features at acute angles that would otherwise be rounded. By way of non-limiting example, the sharp, detailed features can help functionality of the final component for heat transfer augmentation, stress concentration management, or assembly with an adjacent turbine engine component.

Claim 1:
A method (<NUM>, <NUM>) of printing a component (<NUM>) comprising:
receiving (<NUM>, <NUM>) an original model (<NUM>, <NUM>, <NUM>) of the component at a printer (<NUM>);
identifying an acute angle (<NUM>, 130a, 130b, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) in a geometry of the original model (<NUM>, <NUM>, <NUM>);
compensating (<NUM>, <NUM>) the geometry of the original model (<NUM>, <NUM>, <NUM>) at the printer (<NUM>) to create a compensated model (<NUM>, <NUM>, <NUM>), wherein the compensating (<NUM>, <NUM>) includes removing a portion (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) of the original model (<NUM>, <NUM>, <NUM>) at the identified acute angle (<NUM>, 130a, 130b, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>); and
printing (<NUM>, <NUM>), with the printer (<NUM>), the component (<NUM>) based upon the compensated model (<NUM>, <NUM>, <NUM>),
wherein the printed component (<NUM>) is more alike the original model (<NUM>, <NUM>, <NUM>) than the compensated model (<NUM>, <NUM>, <NUM>) due to distortions of the printer (<NUM>) during printing.