3D Printing Interference Sensing for Meltpool And Layer Height
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Solution Overview
Problem
Existing additively manufacturing apparatuses lack the ability to accurately detect relative movements between the object and the powder bed, and determine specific information about the meltpool and consolidated regions, leading to potential imperfections in the manufactured three-dimensional objects.
Innovation Solution
An apparatus that uses a measurement beam source to generate a measurement beam, guided by a beam guiding unit onto the build plane, with a determination device that determines parameters based on optical interference, allowing for the detection of height information and process quality assessment, including the meltpool and consolidated layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a measurement beam source and beam guiding unit are added to guide the measurement beam in the build plane, then measurement precision and information about the additive manufacturing process are improved, but device complexity increases
Solution Approach 1:
The energy source used for consolidating build material is also utilized as a measurement beam source. By detecting radiation emitted from the build material during consolidation, the system performs both manufacturing and measurement functions with a single apparatus, avoiding the need for separate measurement equipment and reducing overall system complexity.
Solution Approach 2:
The build material itself serves as the measurement target by emitting radiation during consolidation. The determination device detects this self-emitted radiation to obtain information about the consolidation process, eliminating the need for external measurement beams or separate probing mechanisms.
2Loss of information
If determination devices are used to generate information about radiation propagating inside the process chamber, then information about the energy source and thermal radiation are obtained, but the ability to detect relative movements and specific meltpool information is insufficient
Solution Approach 1:
The patent replaces mechanical positioning measurement systems with optical detection. By using the determination device to detect radiation characteristics (intensity, spectrum, temporal patterns) from the build material, the system obtains precise information about meltpool state and relative movements without mechanical contact or additional positioning hardware.
Solution Approach 2:
The determination device monitors changes in radiation parameters emitted from the build material during consolidation. By analyzing variations in radiation intensity, wavelength, or temporal patterns, the system derives information about meltpool dynamics, material consolidation state, and any relative movements between the build platform and powder bed.
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 improved process quality control by providing real-time information on the additive manufacturing process, allowing for the identification of deviations and stability analysis, thus ensuring the geometrical and mechanical requirements of the manufactured objects are met.
Implementation Method 1
the determination device is adapted to determine at least one parameter relating to the object and/or the build material layer based on (optical) interference
Data Source
AI summary
Apparatus (1) for additively manufacturing three-dimensional objects (2) by means of successive layerwise selective irradiation and consolidation of layers of a build material (3) which can be consolidated by means of an energy source (5), wherein a measurement beam source (4, 17) is provided which is adapted to generate a measurement beam (7), wherein a beam guiding unit (20) is provided that is adapted to guide the measurement beam (7) in the build plane (6) in the process chamber, wherein a determination device (8) is adapted to determine at least one parameter relating to the object (2) and/or a build material layer (9) based on interference.