3D Component Imaging via External Thermal Detection
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Solution Overview
Problem
The evaluation of individual layer images in additive manufacturing methods like selective laser melting and sintering is complex, making it difficult to assess the quality of components produced.
Innovation Solution
A method involving the use of a detection device outside the laser beam path to capture spatially resolved layer images, composed of multiple individual images, which are then used to generate a three-dimensional image of the component, allowing for precise quality assessment by recording energy input during production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If individual layer images are evaluated separately using traditional methods, then measurement detail is improved, but evaluation complexity increases and quality assessment becomes difficult
Solution Approach 1:
The patent combines multiple individual layer images into a single composite layer image that represents the entire component. This merging process integrates temperature data from all layers into one unified visualization, reducing evaluation complexity while maintaining measurement precision through the composite view.
Solution Approach 2:
The composite layer image serves multiple functions simultaneously: it provides overall quality assessment, displays temperature distribution across the entire component, and enables defect detection without requiring separate analysis of each individual layer, thus simplifying the evaluation process.
2Measurement precision
If detection device is placed inside laser beam path, then measurement accuracy is improved, but device complexity and safety risks increase
Solution Approach 1:
The patent uses the component material itself as an intermediary medium. The material absorbs laser energy and re-emits it as thermal radiation that can be detected from outside the beam path. This eliminates the need for detectors to be positioned in the dangerous laser beam while maintaining measurement capability through thermal imaging.
Solution Approach 2:
The patent replaces direct optical detection within the laser beam path with thermal radiation detection from outside the beam path. By monitoring thermal emission from the material rather than directly measuring laser energy, the system achieves measurement accuracy without the complexity and safety issues of in-beam detection.
3Manufacturing precision
If comprehensive quality control is implemented for large components, then manufacturing precision is improved, but production time increases
Solution Approach 1:
The patent segments the quality control process into automated image capture and automated composite image generation. The detection device captures multiple layer images that are automatically processed and combined into a composite image, enabling comprehensive quality control of large components without manual intervention and minimizing production time delays.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables quick, easy, and precise quality control of components, reducing time and costs, especially for large or complex components, by providing a comprehensive and non-destructive analysis of energy input and material irregularities.
Implementation Method 1
detection device which is designed to detect a spatially resolved measured variable characterizing an energy input into the component, with the detection device being located outside the beam path of a laser
Implementation Method 2
produced by selective laser melting and/or by selective laser sintering
Implementation Method 3
produced by selective laser melting and/or by selective laser sintering
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The method involves determining two layer images of a three-dimensional component (14) during production of the three-dimensional component by a detection device e.g. high-resolution detector. A measured quantity characterizing energy input in the three-dimensional component is detected with spatial resolution by the detection device for each of the layer images. A three-dimensional image (26) of the three-dimensional component is generated based on the determined layer images by a computing device. The three-dimensional image is displayed by a display device. An independent claim is also included for a device for imaging a three-dimensional component.