Additive Manufacturing Calibration Device for Laser Power and Scanner Accuracy
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Solution Overview
Problem
Current calibration methods for laser power and scanner accuracy in additive manufacturing require opening the build chamber, making them time-consuming, offline processes that cannot be performed during product manufacture, especially for large products.
Innovation Solution
An apparatus with a calibration device and guiding means allows the scanning means to move between a production position and a calibration position outside the build chamber, enabling interim calibration without opening the chamber, using sensors to measure and adjust laser power and scanner parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If calibration is performed using existing methods with sensors inside the build chamber, then measurement precision is improved, but productivity deteriorates because the chamber must be opened and the process interrupted
Solution Approach 1:
The calibration function is extracted from the build chamber environment by providing a calibration device with its own sensor system that can receive the beam outside the chamber. The scanning means can move to a calibration position where the beam strikes the calibration device with sensor, separating the calibration measurement function from the production build chamber, thereby enabling calibration without opening the chamber or interrupting the production atmosphere.
Solution Approach 2:
The calibration device acts as an intermediary between the beam source and the build chamber. It provides a dedicated sensor system that interfaces with the beam outside the chamber, mediating the calibration measurement process and eliminating the need to open the build chamber for sensor access, thus maintaining production continuity while enabling precise calibration.
2Measurement precision
If calibration is performed offline by building a product and measuring dimensions, then measurement precision is improved, but loss of time increases due to the lengthy offline process
Solution Approach 1:
The calibration device is pre-configured with known reference positions and a sensor system that can directly measure beam position. This preliminary setup eliminates the need to build actual products for calibration purposes. The scanning means can be calibrated quickly by moving to the calibration position and performing direct measurements against the pre-configured reference system, dramatically reducing calibration time while maintaining precision.
Solution Approach 2:
Instead of using actual product dimensions for calibration, the system uses a calibrated reference system in the calibration device that copies or simulates the measurement function. The sensor in the calibration device creates a virtual reference framework that replaces the need for physical product measurements, enabling fast and accurate calibration without time-consuming product fabrication and measurement cycles.
3Ease of operation
If the build chamber is opened for calibration, then ease of operation is improved, but reliability deteriorates because production pressure and protective atmosphere are compromised
Solution Approach 1:
The measurement function is segmented into two separate systems: the production build chamber and the calibration device. The calibration device has its own sensor system that operates independently outside the chamber. This segmentation allows calibration to be performed on the scanning means without opening the build chamber, maintaining the integrity of the production atmosphere while providing easy access for calibration operations through the mobile calibration device.
Solution Approach 2:
The calibration device serves as an intermediary that performs calibration measurements outside the build chamber. Its sensor system interfaces with the beam in the calibration position, mediating the calibration process and eliminating the need to open the chamber. This preserves the production atmosphere stability while maintaining ease of operation through the dedicated calibration interface.
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 fast and simple calibration of laser power and scanner accuracy during ongoing product manufacture, maintaining production pressure and atmosphere, allowing for regular calibration without interrupting the process.
Implementation Method 1
at least a beam source (9) to generate an energy beam (6)... a closed window (11) that is transparent for the beam so that the beam (6) passes through the window (11) and enters the build chamber (1)
Implementation Method 2
additive manufacturing technique such as selective laser melting... transforming a powder in the build chamber (1) into successively adhered layers of the product (4), when moving the beam (6)
Implementation Method 3
a calibration device (3) for said beam source (9) and/or said scanning means (10)... an actual value is measured for at least a parameter of the optical system (2)
Data Source
Figure 1~2
AI summary
The invention concerns an apparatus and a method for layered manufacture of a three-dimensional product (4) with an optical system (2) that contains at least one beam source (9) to generate an energy beam (6) and corresponding scanning means (10) to move this beam (6), where the apparatus contains a calibration device (3) for said beam source (9) and/or said scanning means (10), wherein at least the scanning means (10) can be moved with respect to the build chamber (1) between a production position and a calibration position, in which the beam (6) can strike a calibration device (3) and thus work in combination with the latter.