Additive Manufacturing Contact Detection Sensor

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Solution Overview

Problem

In powder bed fusion additive manufacturing, unintentional projection portions formed during the fusion process can interfere with the flattening mechanism, leading to shape precision issues and potential damage, as existing detection methods are either unreliable or risk damaging the mechanism.

Innovation Solution

An additive manufacturing apparatus equipped with a contact detection sensor featuring a plate-like probe, such as plate spring groups or pairs, to reliably detect projection portions without damaging the flattening mechanism, allowing for precise detection and removal of these projections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If optical detection method using image capturing apparatus is used to detect projection portions, then detection can be performed without contact, but sufficient detection sensitivity cannot be achieved depending on the shape of the projection portion

Engineering Contradiction:

Improvedetection reliabilityVSAvoiddetection sensitivity

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent replaces the optical detection system with a mechanical contact detection system using a probe that physically touches the projection portions. This mechanical approach provides reliable detection regardless of the projection shape, overcoming the limitation of optical methods where detection sensitivity varies with projection geometry.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The probe acts as an intermediary between the detection system and the projection portions. By physically contacting the projections, the probe translates their presence into detectable signals, providing consistent detection across various projection shapes that optical methods cannot reliably detect.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If load change detection method on driving motor of flattening mechanism is used to detect projection portions, then detection can be performed, but the blade of the flattening mechanism can be damaged by contact

Engineering Contradiction:

Improvedetection capabilityVSAvoidblade damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The probe serves as an intermediary detection element that contacts the projection portions instead of the flattening mechanism blade. This allows load change detection to proceed while protecting the blade from damage, as the probe absorbs the contact stress.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The probe replicates the detection function of the flattening mechanism blade without performing the flattening action. By copying the contact-based detection capability while separating the detection and flattening functions, the system can detect projections without risking blade damage.

Inventive Principle:

Principle #26Copying

3Productivity

If flattening mechanism is used to form powder layer, then powder layer can be formed efficiently, but the flattening mechanism is caught by the projection portion and the step of forming the powder layer is stopped

Engineering Contradiction:

Improvepowder layer formation efficiencyVSAvoidprocess continuity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs preliminary detection of projection portions using the probe before the flattening mechanism operates. By detecting and flagging projections in advance, the system can adjust the flattening process or alert operators, preventing the mechanism from being caught and stopping the process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The probe provides continuous feedback about the presence of projection portions to the control system. This feedback allows the flattening mechanism operation to be adjusted in real-time, preventing contact with projections that would cause process interruption, thereby maintaining both productivity and reliability.

Inventive Principle:

Principle #23Feedback

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

The solution enables reliable detection and removal of projection portions, preventing interference with the flattening mechanism, improving shape precision and preventing damage, thereby stabilizing the additive manufacturing process.

Implementation Method 1

a contact detection sensor 12 including a plate-like probe 14. Presence or absence of a projection portion 25 on a surface of the solidified layer 13 is detected by using the contact detection sensor 12

Methodology Applied

Scientific EffectMechanical contact detection:

Implementation Method 2

an energy beam source configured to radiate an energy beam to the powder layer formed by the powder layer forming portion to fuse or sinter the powder layer so that a solidified layer is formed

Methodology Applied

Scientific EffectEnergy beam radiation: Laser

Data Source

PatentUS11511351B2Additive manufacturing apparatus and method for manufacturing three-dimensionally shaped object

Publication Date: 2022.11.29 CANON KK

AI summary

An additive manufacturing apparatus includes a powder layer forming portion, an energy beam source, and a contact detection sensor including a plate-like probe. The powder layer forming portion is configured to form a powder layer in a predetermined region. The energy beam source is configured to radiate an energy beam to the powder layer formed by the powder layer forming portion to fuse or sinter the powder layer so that a solidified layer is formed. Presence or absence of a projection portion on a surface of the solidified layer is detected by using the contact detection sensor.