3D Printing Multi-Phase Sensing for In-Situ Defect Repair
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional post-processing techniques in additive manufacturing face limitations in quality assurance and efficiency, particularly in detecting and addressing defects in 3D printed parts, which can lead to manufacturing latencies and quality issues.
Innovation Solution
A multi-phase sensor system comprising an image sensor and an eddy current sensor that work in concert to detect defects in real-time by determining the landing location of ejected material during the printing process, allowing for immediate identification and potential in-situ repair of defects such as spatter, voids, and unsintered powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional post-processing techniques are used for quality assurance, then manufacturing throughput is maintained, but defect detection capability and quality accuracy are insufficient
Solution Approach 1:
The patent implements real-time sensing systems that detect defects during the additive manufacturing process itself, rather than performing inspection after manufacturing is complete. The sensor system continuously monitors the build process, identifying defects such as spatter, voids, and unsintered powder as they occur, enabling immediate detection without requiring separate post-processing inspection time.
Solution Approach 2:
The patent replaces conventional mechanical post-processing inspection methods with non-contact optical sensing systems. The sensor system uses optical fields to detect defects in the printed part, eliminating the need for physical contact or manual inspection processes that add time to the manufacturing cycle.
2Measurement precision
If real-time sensing is implemented during printing, then defect detection accuracy is improved, but system complexity increases
Solution Approach 1:
The patent divides the sensing system into multiple specialized sensors, each optimized for detecting specific types of defects. The sensor system includes sensors positioned at different locations and orientations, with each sensor targeting particular defect characteristics. This segmentation allows the system to achieve high detection accuracy for various defect types while keeping each individual sensor relatively simple.
Solution Approach 2:
The patent designs a sensor system that can detect multiple types of defects (spatter, voids, unsintered powder, dimensional inaccuracies) using a unified sensing platform. The system processes various sensor inputs through a common image processing and analysis framework, reducing overall system complexity compared to having separate specialized systems for each defect type.
3Reliability
If multiple sensors are deployed at different locations, then comprehensive defect coverage is achieved, but sensing system complexity and cost increase
Solution Approach 1:
The patent combines multiple sensing functions and multiple sensors into an integrated sensing system that operates as a unified platform. The sensors are coordinated to work together, with their data processed through a common analysis system. This merging approach achieves comprehensive defect coverage while reducing the complexity that would result from operating multiple independent sensing systems.
Solution Approach 2:
The patent positions sensors at different hierarchical levels, with sensors mounted on moving components (such as the recoater) that traverse the build volume. This nested arrangement allows sensors to access different regions of the printed part during various stages of the manufacturing process, achieving comprehensive coverage through coordinated movement rather than requiring all sensors to be stationary and simultaneously positioned.
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
Enhances the quality and accuracy of 3D printing by enabling real-time detection and correction of defects, reducing post-processing times and ensuring higher manufacturing throughput while maintaining quality standards.
Implementation Method 1
a first sensor (e.g., an image sensor, optical camera, infrared imager, etc.) configured to determine a landing location of matter ejected during heating of print material to form a weld pool
Implementation Method 2
a second sensor (e.g., an eddy current sensor, etc.) configured to detect a defect in the build piece based on the determination of the landing location
Data Source
AI summary
In various aspects, 3D printers, and sensor systems coupled to or integrated with the 3D printers are disclosed. The sensor systems may include image and second sensors for detecting potential defects or print artifacts. During printing, an energy beam source forms a weld pool by melting selected regions of print material, which solidifies to produce the build piece. The image sensor may image an area including the weld pool to determine a landing location of matter ejected during the heating of print material to form the weld pool. The second sensor may detect a defect in the build piece based on the determination of the landing location. Print operation may be suspended while the sensor data is used to repair the defect, after which 3D printing resumes. In this way, for example, high quality build pieces can be produced with reduced post-processing times, and hence a higher manufacturing throughput.