Additive Manufacturing Calibration via Test Mark Delay Optimization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Additive manufacturing systems face accuracy errors due to synchronization issues with high power laser positioning systems, particularly in metal object production, caused by timing errors, ramp up/ramp down behavior, and dynamic scanner behavior, which require labor-intensive optimization of delay settings.
Innovation Solution
A method for calibrating additive manufacturing apparatuses involves making test marks at different delay settings to determine optimal delay settings for the solidifying device and deflector unit, including on/off, jump, and mark delays, using a calibration system with a sensor unit to improve accuracy and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If labor-intensive manual optimization of delay settings is used, then calibration accuracy can be improved, but calibration time and complexity increase significantly
Solution Approach 1:
The system performs self-calibration by automatically determining optimal delay settings through test marks and image processing, eliminating the need for manual operator intervention while maintaining high calibration accuracy
Solution Approach 2:
Manual mechanical adjustment of delay settings is replaced with an automated digital system that uses image capture, processing algorithms, and automatic parameter determination to establish optimal calibration values
2Reliability
If manual calibration by skilled operators is used, then calibration quality can be improved, but operator dependency and subjectivity increase
Solution Approach 1:
The system captures images of test marks, processes them through algorithms to determine actual positions, compares these with target positions, and automatically adjusts delay settings based on this feedback loop, eliminating subjectivity and operator dependency
Solution Approach 2:
Human operator judgment and manual adjustment are replaced with automated image processing algorithms that objectively determine optimal delay settings based on measured test mark positions
3Productivity
If high power laser positioning systems are used, then manufacturing speed can be improved, but synchronization errors and accuracy errors increase
Solution Approach 1:
The system performs preliminary calibration by creating test marks at different delay settings before actual manufacturing, determining optimal delay values in advance to compensate for laser ramp-up/ramp-down behavior and scanner dynamics during high-speed operation
Solution Approach 2:
The system dynamically adjusts delay parameters based on measured test mark positions, optimizing the timing synchronization between laser emission and scanner position to maintain positioning accuracy at high manufacturing speeds
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 method enhances the accuracy and speed of calibration, allowing for reproducible and objective calibration independent of the user or apparatus, reducing the risk of high energy density issues and improving the precision of layer solidification in additive manufacturing.
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
the apparatus includes a deflector unit for deflecting the electromagnetic radiation along the surface level
Data Source
AI summary
A method for calibrating an apparatus for producing an object by additive manufacturing, the apparatus including a process chamber for receiving a bath of material to 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 electromagnetic radiation, the method including controlling the solidifying device to make a first test mark at a first delay setting, controlling the solidifying device to make a second test mark at a second delay setting different from the first delay setting, and determining a delay setting based on at least the first test mark and the second test mark.