Additive Manufacturing Calibration Element for Energy Beam Alignment
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Solution Overview
Problem
Existing additive manufacturing apparatuses face challenges in accurately calibrating energy beams, which affects the quality and consistency of three-dimensional object production.
Innovation Solution
The apparatus incorporates a calibration element with multiple calibration sections that emit measurement radiation when irradiated by the energy beam. A determination unit detects this radiation, and a control unit calibrates the irradiation device based on the detection, allowing for precise alignment and positioning of the energy beam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a calibration element with multiple calibration sections is introduced to improve calibration accuracy, then the measurement precision and manufacturing precision are improved, but the device complexity increases
Solution Approach 1:
The calibration element is divided into multiple calibration sections, each with specific geometric features that reflect different calibration parameters. This segmentation allows simultaneous calibration of multiple beam parameters (position, orientation, focus) by analyzing radiation from different sections, thereby improving measurement precision while keeping the calibration element as a single integrated component.
Solution Approach 2:
The calibration element acts as an intermediary object between the energy beam and the determination unit. It converts the energy beam parameters into measurable radiation patterns that can be detected and analyzed, enabling indirect but precise measurement of beam characteristics without requiring direct access to the beam source or complex direct measurement apparatus.
2Manufacturing precision
If parameters of radiation are determined throughout the additive manufacturing process to improve process quality, then the manufacturing precision is improved, but the loss of time occurs due to continuous measurement
Solution Approach 1:
The calibration element is pre-positioned in the build chamber before the additive manufacturing process begins. The determination unit is pre-configured to monitor specific radiation parameters from known calibration sections. This preliminary setup enables continuous passive monitoring during manufacturing without requiring real-time intervention or additional measurement steps, thereby maintaining manufacturing precision while minimizing time loss.
Solution Approach 2:
The determination unit continuously monitors radiation parameters from the calibration sections throughout the entire additive manufacturing process without interruption. This continuous monitoring provides real-time feedback on beam stability and drift, enabling immediate corrective actions if parameters deviate from specifications, thereby maintaining consistent process quality without periodic stoppages for measurement.
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 solution enhances the calibration accuracy of the energy beam, leading to improved process quality and consistency in additive manufacturing, ensuring that the energy beam is properly guided and focused onto the build material.
Implementation Method 1
the calibration element comprises at least one calibration section that is adapted to emit measurement radiation upon irradiation with the or an energy beam
Data Source
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AI summary
Apparatus (1) for additively manufacturing three-dimensional objects by means of successive layerwise selective irradiation and consolidation of layers of a build material which can be consolidated by means of at least one energy beam (4), wherein an irradiation device (2) is adapted to generate and guide the energy beam (4) to at least one position of a build plane (6), wherein a determination unit (7) is adapted to determine at least one parameter of radiation propagating in a process chamber (8) of the apparatus (1), wherein a calibration element (9) is arrangeable or arranged in the process chamber (8), wherein the calibration element (9) comprises at least one calibration section (11 - 19) that is adapted to emit measurement radiation (20) upon irradiation with the or an energy beam (4) and in that the determination unit (7) is adapted to detect the measurement radiation (20), wherein a control unit (21) is adapted to calibrate the irradiation device (2) dependent on the detection of the measurement radiation (20) emitted by the at least one calibration section (11 - 19).