3D Printing Calibration via Overlapping Scanning Units
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Solution Overview
Problem
Existing methods for calibrating manufacturing devices used in additive manufacturing, such as selective laser sintering, fail to compensate for system drifting due to temperature influences or mechanical setting phenomena over time, leading to reduced precision and accuracy in producing three-dimensional objects.
Innovation Solution
A calibration method utilizing multiple scanning units with overlapping scanning regions and monitoring units to detect positional deviations and compensate for them in real-time, allowing for continuous calibration during the production process, thereby improving the precision of the three-dimensional objects by adjusting the beam positions and correcting for any discrepancies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If test patterns are produced and detected by a camera for calibration, then initial calibration can be performed, but system drifting during the building process and over longer periods cannot be compensated
Solution Approach 1:
The patent implements continuous feedback by using monitoring units to detect the actual positions of beams from scanning units in real-time during the building process. The control unit receives this feedback information and uses it to determine correction values that compensate for any deviations, thereby maintaining calibration precision throughout the entire manufacturing process rather than relying on initial calibration alone.
Solution Approach 2:
The calibration process is transformed from a discrete initial step into a continuous action that occurs throughout the entire building process. Monitoring units continuously track beam positions, and the control unit continuously calculates and applies correction values, ensuring that calibration is maintained without interruption throughout the manufacturing process.
2Manufacturing precision
If multiple scanning units with overlapping regions are used, then real-time calibration during production is enabled, but device complexity increases
Solution Approach 1:
The monitoring units serve multiple functions: they monitor beam positions for calibration purposes, detect positional deviations in real-time, and provide data for calculating correction values. This multi-functionality reduces the need for separate calibration devices and integrates calibration capabilities into the existing manufacturing system, thereby reducing overall system complexity despite the use of multiple scanning units.
Solution Approach 2:
The calibration function is merged with the manufacturing process by using the same scanning units and build area for both production and calibration activities. The monitoring units are integrated into the existing system architecture, and correction values are applied during normal manufacturing operations, combining what were previously separate functions into a unified system.
3Manufacturing precision
If beam positions are continuously monitored and corrected, then precision is maintained throughout the process, but measurement and detection complexity increases
Solution Approach 1:
The monitoring units act as intermediaries between the scanning units and the control unit. They detect beam positions and convert this information into a format suitable for the control unit to process, simplifying the measurement task by providing pre-processed data that directly indicates positional deviations without requiring complex analysis of raw sensor data.
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 method enhances the precision of three-dimensional object production by enabling real-time compensation for positional deviations, improving dimensional accuracy and surface texture, and maintaining high precision throughout the manufacturing process.
Implementation Method 1
At least a first of the at least two scanning units is assigned a first monitoring unit whose monitoring region extends to a target point of the first scanning unit... evaluating an output signal of the first monitoring unit
Implementation Method 2
selectively solidifying a building material, preferably a powder... selectively irradiating positions in the so-called powder bed that correspond to a cross-section of the object to be produced
Implementation Method 3
the building material is in each layer selectively solidified by means of a laser beam
Data Source
AI summary
A calibration method serves for calibrating a manufacturing device for additively producing a three-dimensional object by applying layer by layer and selectively solidifying a building material. The manufacturing device comprises at least two scanning units, each of which is capable of directing a beam to different target points in the working plane, which are located within a scanning region assigned to the respective scanning unit, wherein the scanning regions region of the at least two scanning units overlap in an overlap area. At least a first of the at least two scanning units is assigned a first monitoring unit whose monitoring region extends to a target point of the first scanning unit and its proximity, wherein a change of a position of the monitoring region is carried out as a function of a change of a position of the target point.