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Method and system for quality assurance and control of additive manufacturing process

A technology of additive manufacturing and energy, applied in the field of additive manufacturing of three-dimensional objects

Active Publication Date: 2020-01-17
MONASH UNIV
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

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Problems solved by technology

However, there is already an inherent delay in laser feedback control if the cooling characteristics of the solidified powder are monitored

Method used

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  • Method and system for quality assurance and control of additive manufacturing process
  • Method and system for quality assurance and control of additive manufacturing process
  • Method and system for quality assurance and control of additive manufacturing process

Examples

Experimental program
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Effect test

Embodiment Construction

[0074] see figure 1 , selective laser melting system 10 progressively builds three-dimensional part 16 layer by layer by solidifying selected regions of powder material sequentially deposited into layers 14 (on build stage 12 within build chamber 36 ). The build chamber 36 has viewing windows 28 (typically semi-transparent laser shield windows) for safe viewing of the build process.

[0075] The uppermost layer 18 of powder material is exposed to a laser beam 22 from a scanning laser head 20 . Laser beam 22 is scanned across powder bed 18 in a predetermined raster pattern in the direction indicated by arrow 24 . A laser melt pool 46 is formed where the laser beam 22 is incident on the powder material. The molten pool 46 follows the laser beam 22 as it scans across the raster pattern, leaving the molten material to cool and solidify. Once the predetermined raster pattern has been completed, a new layer of powder material is deposited as the floor 26 of the build table 12 is ...

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Abstract

An additive manufacturing system and method is provided for fabricating 3D objects (16) from successive layers (14) of material. The additive manufacturing system (10) has an energy projection assembly (20) for inputting energy (22) into a specified area within the layer (18) to consolidate the material; a plurality of image sensors (30, 32, 34), each of the image sensors having a corresponding field of view (35, 40, 42) covering at least part of the layer (18) of material, such that each of the fields of view at least partially overlap with the field of view of at least one other of the imagesensors; and an image processor (56) to capture image data from each of the image sensors (30, 32, 34). The image processor (56) controls exposure times for each of the image sensors (30, 32, 34) andcombines the image data from the image sensors to provide a single, spatially resolved image of the energy being input throughout the specified area for each layer (14) of material respectively for comparison against threshold data values to locate potential consolidation defects in the specified area.

Description

technical field [0001] The invention relates to the additive manufacturing of three-dimensional objects by sequentially depositing and consolidating layers of the object. In particular, the present invention relates to powder bed fusion (PBF), such as selective laser sintering (SLS), electron beam melting (EBM), selective laser melting (SLM). Background technique [0002] Selective laser sintering (SLS), selective laser melting (SLM), and electron beam melting (EBM) are typical methods of powder bed fusion (PBF) manufacturing. Successive layers of raw material in powder form are deposited and cured in defined areas (corresponding to the layers of the three-dimensional object) until the three-dimensional object is completed. This allows making objects with complex geometries that are not possible using casting or molding techniques. [0003] Defined areas of the powder material are sintered or melted using an applied energy source such as a laser or electron beam. The prec...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): B33Y30/00B33Y50/02B29C64/393
CPCB22F12/00B22F10/28B22F10/85B22F10/364B22F10/366B22F10/38B22F12/90B22F12/41B29C64/153B29C64/268B29C64/393B29C64/20B28B1/001B33Y10/00B33Y30/00B33Y50/02G05B19/4099H01J37/305H01J37/304Y02P10/25B22F2999/00B29C64/245B22F2203/03B22F10/16B22F10/00B22F2998/10B22F10/10
Inventor M·于尔格A·莫洛特尼科夫
Owner MONASH UNIV