Additive Manufacturing Calibration via Imaging and Correction Vectors
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Solution Overview
Problem
Current methods for calibrating additive manufacturing apparatuses, particularly for metal objects, lack the accuracy and speed required to meet the demands of modern manufacturing, as they fail to precisely solidify selective parts of layers during the 3D printing process.
Innovation Solution
A method involving a calibration system with an imaging device that determines the position of a calibration marker and a solidifying marker, calculates a correction vector, and adjusts the solidifying device to improve accuracy, using electromagnetic radiation and thermal conditioning to ensure precise alignment and minimize distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional calibration methods are used, then the calibration process is simple, but the accuracy and speed of calibration do not satisfy current demands in additive manufacturing
Solution Approach 1:
The patent introduces an intermediary calibration object with known geometric features that serves as a mediator between the imaging device and the solidifying device. This calibration object contains reference markers with precisely known positions and geometric characteristics, allowing the system to determine positional inaccuracies and calculate correction vectors without requiring direct measurement of the solidifying device's actual positions.
Solution Approach 2:
The patent replaces direct mechanical measurement and adjustment methods with an optical imaging-based calibration system. Instead of using mechanical tools to measure and adjust the solidifying device positions directly, the system uses an imaging device to capture images of the calibration object, processes these images to determine positional deviations, and calculates correction vectors to adjust the solidifying device, thereby substituting mechanical measurement with optical measurement and computational correction.
2Manufacturing precision
If calibration is performed frequently to improve accuracy, then manufacturing precision improves, but production time increases
Solution Approach 1:
The patent performs calibration before the actual manufacturing process begins. By establishing accurate correction vectors through preliminary calibration using the calibration object, the system ensures that subsequent solidification operations proceed with high precision without requiring frequent interruptions for recalibration, thereby maintaining both high manufacturing precision and production speed.
Solution Approach 2:
The patent implements a feedback mechanism where the imaging device continuously monitors the position of the calibration object and the solidifying device, compares actual positions against predetermined values, and calculates correction vectors. This feedback loop allows for real-time or near-real-time adjustment of the solidifying device positions, ensuring maintained accuracy without significant production time loss.
3Measurement precision
If thermal conditioning is applied to minimize distortion, then measurement precision improves, but energy consumption increases
Solution Approach 1:
The patent applies thermal conditioning to the calibration object and/or the solidifying device to control and stabilize temperature parameters. By maintaining specific temperature ranges or applying controlled thermal fields, the system minimizes thermal distortion and positional variations that would otherwise affect measurement precision. This parameter control ensures accurate position measurements while the energy consumption is managed through targeted thermal application rather than continuous heating.
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 enhances the accuracy and reproducibility of the additive manufacturing process, allowing for faster and more precise production of complex geometries by correcting for positional inaccuracies and thermal variations, thereby improving the overall quality and efficiency of the manufacturing process.
Implementation Method 1
a solidifying device for solidifying a selective layer-part of the material on the surface level by means of electromagnetic radiation
Implementation Method 2
A laser comprised in the computer controlled additive manufacturing apparatus follows these settings and vectors to solidify successive layers of material
Implementation Method 3
providing a calibration system with an imaging device that can be directed to said support; determining, with the imaging device, a measure for the position of the calibration marker
Data Source
AI summary
A method for calibrating an apparatus for producing an object by means of additive manufacturing including a process chamber for receiving a bath of material which can be solidified by exposure to electromagnetic radiation, a support for positioning the object in relation to the surface level of the bath of material, and a solidifying device for solidifying a selective layer-part of the material on the surface level by means of electromagnetic radiation. A method including providing, on or near the support, a calibration marker that faces the solidifying device, and providing a calibration system with an imaging unit that can be directed to the support. The method further includes a determining step of the position of the calibration marker, making a solidifying marker that relates to the calibration marker and determining a measure for the position thereof, and determining, with the calibration system, at least a correction vector based on the positions of both the calibration marker and the solidifying marker.