3D Printing Energy Beam Calibration via Pre-Printed Markers
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Solution Overview
Problem
In 3D printing, variations in the position of an energy beam can lead to errors and defects in the generated object due to uneven energy delivery, causing deviations in the formation of layers and ultimately affecting the accuracy and quality of the final product.
Innovation Solution
A system comprising a platform, an energy source, a guidance system, and a detector that calibrates the energy beam's position and shape by forming markers on a target surface, detecting their deviations, and adjusting the guidance system to ensure precise alignment and printing of three-dimensional objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the energy beam position is not calibrated, then the printing process can proceed without additional calibration steps, but the manufacturing precision and quality of the printed object deteriorate due to position deviations and uneven energy delivery
Solution Approach 1:
The patent applies preliminary action by performing calibration before the actual printing process. A calibration object with known geometric features is printed first, allowing the system to determine and store correction data for the energy beam's actual position relative to the intended position. This pre-calibration ensures that subsequent printing operations maintain high precision without requiring continuous complex adjustments during production.
Solution Approach 2:
The patent uses a calibration object that replicates known geometric patterns (such as grids or patterns with specific feature spacings) to indirectly measure the energy beam's positioning accuracy. By printing this copy of a known pattern and comparing the actual printed dimensions to the intended dimensions, the system can calculate position deviations and generate correction data without directly measuring the beam position in real-time during printing.
2Measurement precision
If calibration markers and detection systems are added, then the manufacturing precision improves through accurate position correction, but the device complexity and difficulty of detecting and measuring increase
Solution Approach 1:
The calibration object incorporates features with distinct visual or detectable characteristics (such as variations in reflectivity, absorption, or emission properties) that allow the detection system to easily identify and measure their positions. These contrasting features create clear signals for the detector, enabling precise measurement of the calibration pattern's actual dimensions and thereby determining energy beam position accuracy without complex measurement procedures.
Solution Approach 2:
The patent employs a calibration object that is a simplified copy or representation of the intended printed pattern, containing recognizable geometric features (such as lines, squares, or grids) with known dimensions. By printing this copy and measuring its actual dimensions, the system can derive position correction data through straightforward geometric comparisons, avoiding the need for complex real-time position detection during the actual printing process.
3Reliability
If the energy beam position varies, then the printing process can be simpler without position correction mechanisms, but the reliability and quality of the printed object deteriorate due to errors and defects
Solution Approach 1:
The patent applies preliminary action by performing calibration before the actual printing process. A calibration object with known geometric features is printed first, allowing the system to determine and store correction data for the energy beam's actual position relative to the intended position. This pre-calibration ensures that subsequent printing operations maintain high precision without requiring continuous complex adjustments during production.
Solution Approach 2:
The patent implements feedback by using the calibration process to generate correction data that is fed back into the printing control system. The measured position deviations from the calibration object are processed to create lookup tables or correction algorithms that automatically adjust the energy beam positioning for subsequent printing operations, ensuring consistent quality and reliability throughout production.
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
This calibration method enhances the accuracy and quality of 3D printing by ensuring consistent energy delivery and precise layer formation, reducing errors and defects in the printed objects.
Implementation Method 1
A 3D printing system may use an energy beam projected on a material bed to transform a portion of pre-transformed material during formation of the 3D object
Implementation Method 2
A 3D printing system may use an energy beam projected on a material bed to transform a portion of pre-transformed material during formation of the 3D object. At times, a position of the energy beam projected on the material bed may vary from a commanded position of the energy beam on the material bed.
Implementation Method 3
a detector that can detect a formed marker in or on the target surface
Implementation Method 4
the at least one controller is configured to direct using the evaluation to adjust the guidance system to print the at least one three-dimensional object
Data Source
AI summary
The present disclosure provides various apparatuses, systems, software, and methods for three-dimensional (3D) printing. The disclosure delineates various optical components of the 3D printing system, their usage, and their optional calibration. The disclosure delineates calibration of one or more components of the 3D printer.