Additive Manufacturing Coordinate Correction for Thermal Misalignment
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Solution Overview
Problem
Existing additive manufacturing methods suffer from positional misalignment between the build table and the base plate due to thermal displacement, leading to inefficiencies and potential tool load issues during cutting processes.
Innovation Solution
Implement a method and apparatus that includes heating and cooling steps for the build table, accompanied by measurement and correction of positional misalignment using a measuring device to adjust the coordinate system before and after these temperature changes, ensuring precise alignment during the formation and cutting of solidified layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the build table is heated and cooled during additive manufacturing, then stress relief and martensitic transformation control are achieved, but positional misalignment occurs between the build table and base plate due to thermal displacement
Solution Approach 1:
The patent measures positional misalignment of the base plate after heating the build table to the preheating temperature, before performing additive manufacturing. This preliminary measurement allows the coordinate system to be corrected in advance, compensating for thermal displacement before it affects manufacturing precision. The same approach is applied after cooling before cutting processes.
Solution Approach 2:
The patent implements a feedback mechanism where a measuring device continuously monitors the positional misalignment of the base plate in the horizontal and vertical directions. The measured misalignment data is used to correct the coordinate system used in additive manufacturing and cutting processes, creating a closed-loop control system that compensates for thermal displacement effects.
2Manufacturing precision
If a larger machining allowance is set to anticipate positional misalignment, then alignment issues are covered, but manufacturing time increases and tool load increases
Solution Approach 1:
By implementing real-time measurement and coordinate system correction, the patent eliminates the need for excessive machining allowances. The feedback mechanism ensures that the actual positional accuracy meets requirements without adding extra material that would need to be removed, thereby reducing both manufacturing time and tool load.
Solution Approach 2:
The patent dynamically adjusts the coordinate system parameters based on measured positional misalignment. This parameter change allows the system to adapt to thermal displacement without requiring fixed safety margins or larger machining allowances, optimizing both precision and efficiency.
3Manufacturing precision
If coordinate system correction is performed after temperature changes, then positional accuracy is maintained, but additional measurement and correction steps are required
Solution Approach 1:
The patent combines the measurement and coordinate system correction steps into the existing heating and cooling cycles. The measuring device is integrated into the additive manufacturing apparatus, and the coordinate correction is performed as part of the temperature change sequence, rather than as separate standalone operations. This merging reduces overall process complexity.
Solution Approach 2:
The system performs self-correction by automatically measuring its own positional misalignment and adjusting the coordinate system accordingly. The additive manufacturing apparatus uses its own measuring device to detect and compensate for thermal displacement, eliminating the need for external intervention or complex manual adjustment procedures.
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 effectively suppresses the adverse effects of thermal displacement-induced misalignment, allowing for precise formation and cutting of three-dimensional objects by continuously correcting the coordinate system, thereby enhancing manufacturing accuracy and efficiency.
Implementation Method 1
a heating step of heating a build table to which a base plate is fixed to a preheating temperature
Implementation Method 2
a cooling step of cooling the build table to a cooling temperature lower than the preheating temperature
Implementation Method 3
forming a solidified layer by irradiating the material layer heated to the preheating temperature with a laser beam or an electron beam
Implementation Method 4
forming a solidified layer by irradiating the material layer heated to the preheating temperature with a laser beam or an electron beam
Data Source
AI summary
An additive manufacturing method includes a heating step, a manufacturing step, a cooling step, a cutting step, a first correction step, and a second correction step. In the heating step, a build table is heated to a preheating temperature. In the manufacturing step, a solidified layer is formed. In the cooling step, the build table is cooled to a cooling temperature. In the cutting step, a cutting process is performed on the solidified layer. In a first correction step executed after the heating step and before the manufacturing step, a positional misalignment of the base plate is measured, and a coordinate system used in the manufacturing step is corrected. In a second correction step executed after the cooling step and before the cutting step, a positional misalignment of the base plate is measured, and a coordinate system used in the cutting step is corrected.