Additive Manufacturing Layer Correction via Real-Time Measurement
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Solution Overview
Problem
Traditional manufacturing techniques, such as subtractive methods, are limited in shape versatility and costly for small batches, while additive manufacturing faces challenges in achieving precise manufacturing tolerances due to internal stress and warping from temperature variations.
Innovation Solution
An additive manufacturing method that involves online adaptation of layer definitions based on real-time measurements of material layers, using a movable measuring head and control unit to adjust production parameters, ensuring accurate and precise layer formation and correcting for thermal effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If additive manufacturing techniques are used to produce workpieces, then productivity and cost-efficiency are improved, but manufacturing precision deteriorates due to internal stress and warping from temperature variations
Solution Approach 1:
The patent applies preliminary action by performing a measurement of the first material layer before producing subsequent layers. The measuring head captures dimensional data of the freshly deposited layer, and this measurement information is used to adaptively adjust production parameters for the next layer, preventing cumulative dimensional errors before they occur.
Solution Approach 2:
The patent implements feedback by using the measurement results of each produced material layer to dynamically adapt the production parameters for subsequent layers. The control unit processes the measured dimensional data and automatically adjusts layer definition parameters, creating a closed-loop control system that maintains manufacturing precision throughout the additive manufacturing process.
2Manufacturing precision
If traditional subtractive manufacturing techniques are used, then manufacturing precision is maintained, but productivity and cost-efficiency deteriorate for small batch production
Solution Approach 1:
The patent applies parameter changes by dynamically modifying production parameters based on measured dimensional data. The system changes layer thickness, deposition speed, or other manufacturing parameters in real-time based on feedback from the measuring head, enabling additive manufacturing to achieve precision comparable to subtractive methods while maintaining its productivity advantages.
3Manufacturing precision
If adaptive adjustment of production parameters based on real-time measurements is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent applies merging by integrating the measuring head and production system into a single coordinated unit. The measurement and production functions are combined in one system, with the control unit managing both operations, thereby reducing the need for separate measurement and manufacturing equipment and simplifying the overall system architecture.
Data Source
AI summary
A method of producing a workpiece includes obtaining CAD data representing the workpiece in multiple workpiece layers. The CAD data includes multiple workpiece layer definitions corresponding respectively to the workpiece layers. The method includes selecting a first workpiece layer definition, preparing a powder bed of powder material on a build platform, and producing, based on the selected workpiece layer definition, a workpiece layer on the build platform by controlling a layer tool to selectively melt or sinter the powder material on the build platform. The method includes assessing the produced workpiece layer, including measuring the produced workpiece layer using a measuring head, analyzing the measurements of the produced workpiece layer, and, in response to the analysis indicating that the produced workpiece layer is defective, reprocessing the produced workpiece layer by controlling the layer tool to selectively melt or sinter the powder material on the build platform.