3D Printing Heat Source Calibration via Absorption Modifiers
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Solution Overview
Problem
Existing methods for calibrating heat sources in 3D printing processes for particulate materials are inadequate, leading to unexpected variations in temperature control, resulting in poor object quality and reliability due to non-uniform heating.
Innovation Solution
A method involving a layer cycle with multiple power profiles for heat sources, where absorption modifiers are used to selectively heat regions, and thermal sensors measure temperatures to adjust power profiles, ensuring target temperatures are consistently met across the build bed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If known calibration methods using thermal sensors are applied, then temperature measurement capability is provided, but unexpected variation in subsequent build process occurs due to inadequate calibration accuracy
Solution Approach 1:
The patent applies preliminary action by performing calibration measurements on multiple calibration layers (at least three layers) before the actual build process. Temperature measurements are taken at different vertical positions within the build bed to establish a comprehensive thermal profile. This preliminary characterization of the thermal field allows the system to account for non-uniform heating patterns and predict temperature variations in subsequent builds, thereby improving build process consistency.
Solution Approach 2:
The patent implements feedback by using measured temperature data from calibration layers to adjust and optimize the heating process. The thermal sensor data collected during calibration is fed back into the control system to refine temperature profiles and compensate for non-uniformities. This feedback mechanism enables continuous improvement of temperature control accuracy in subsequent build operations.
2Temperature
If heat sources operate at high input power to achieve melting temperature, then fusing of particulate material is achieved, but significant temperature differentials arise between fused and unfused areas
Solution Approach 1:
The patent applies local quality by spatially varying the heating parameters across different regions of the build bed. The system identifies areas with different thermal characteristics through calibration measurements and applies localized compensation. By adjusting heating power based on position-specific thermal responses, the system achieves uniform temperature distribution across the entire build bed, preventing excessive temperature differentials between fused and unfused areas.
Solution Approach 2:
The patent implements dynamics by making the heating process adaptive and variable rather than static. The system dynamically adjusts heating parameters based on real-time temperature measurements and calibration data. Power levels are modulated in response to measured temperature variations, allowing the system to maintain temperature uniformity while achieving the required melting temperature for fusing.
3Stability of the object's composition
If heat source input power is varied along one direction to reduce non-uniformities, then temperature uniformity improves, but device complexity increases due to multiple power profiles
Solution Approach 1:
The patent applies segmentation by dividing the build bed into multiple measurement zones and assigning specific calibration procedures to each zone. Temperature measurements are taken at different vertical positions and horizontal locations, creating a segmented thermal map. This segmentation allows the system to manage complexity by treating each zone independently with its own calibration data, rather than attempting to control the entire build bed as a single uniform region.
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 approach reduces temperature variations, improving the uniformity and reliability of the 3D printing process by adjusting heat source power profiles based on measured temperatures, leading to better control over the heating process and object quality.
Implementation Method 1
a thermal sensor, such as a pyrometer or thermal camera that detects the temperature of the build bed surface
Implementation Method 2
depositing absorption modifier in the form of radiation absorber over each region
Data Source
AI summary
A method for calibrating heat source(s) in an apparatus for manufacturing 3D objects including layer cycle steps of: distributing a layer of particulate material over a build bed; heating the layer with a heat source at a first power profile; measuring a set of temperatures at multiple regions; depositing absorption modifier (absorber) over each region and/or depositing absorption modifier (inhibitor) over a surrounding area; heating each region with the heat source or a second heat source at a second input power profile; and measuring a second set of temperatures at each region; repeating the layer cycle using different input power profiles; and determining an adjusted first and/or second input power profile, wherein when applied during a subsequent layer cycle, causes a subsequent measured set of temperatures to be within a range of target temperatures, such that the ranges are reduced over those measured for each of the calibration layers.