3D Additive Manufacturing Real-Time Defect Correction
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Solution Overview
Problem
Conventional three-dimensional additive manufacturing methods require long work times and do not allow for real-time defect detection, leading to wasted time and resources due to the inability to inspect modeling defects until completion, resulting in reduced productivity.
Innovation Solution
A three-dimensional additive manufacturing device equipped with sensors to monitor roughness and temperature on the powder bed and modeling surface, enabling real-time correction of defects before the next layer is formed, thereby preventing modeling failures and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive manufacturing methods are used to manufacture large three-dimensional shaped products by repeatedly stacking sintered layers, then the product can be manufactured, but the work time becomes extremely long (several tens of hours)
Solution Approach 1:
The patent implements real-time feedback mechanisms through sensors that continuously monitor the modeling process. The sensor detects abnormalities in the sintered layers during manufacturing, and this information is fed back to the control unit, which automatically adjusts processing parameters or halts the process to prevent defects, thereby maintaining high product quality while reducing overall work time by avoiding rework.
Solution Approach 2:
The patent performs preliminary defect detection during the manufacturing process itself rather than after completion. By using sensors to detect abnormalities in real-time and correcting them immediately, the system prevents defects from propagating through subsequent layers, eliminating the need for time-consuming post-manufacturing inspection and reducing total work time.
2Productivity
If conventional additive manufacturing methods are used without in-process inspection, then the manufacturing process can proceed continuously, but modeling defects are only detected after completion, causing the entire product to be discarded
Solution Approach 1:
The patent implements real-time feedback mechanisms through sensors that continuously monitor the modeling process. The sensor detects abnormalities in the sintered layers during manufacturing, and this information is fed back to the control unit, which automatically adjusts processing parameters or halts the process to prevent defects, thereby maintaining high product quality while reducing overall work time by avoiding rework.
Solution Approach 2:
The patent performs preliminary defect detection during the manufacturing process itself rather than after completion. By using sensors to detect abnormalities in real-time and correcting them immediately, the system prevents defects from propagating through subsequent layers, eliminating the need for time-consuming post-manufacturing inspection and reducing total work time.
3Reliability
If real-time sensor monitoring and correction mechanisms are added to the additive manufacturing device, then defect detection capability is improved, but the device complexity increases
Solution Approach 1:
The patent integrates multiple functions into the control unit, which not only receives sensor signals for defect detection but also controls the beam emitting unit, adjusts processing parameters, and manages the overall manufacturing process. This multi-functionality reduces the need for separate dedicated components for each function, thereby limiting the increase in device complexity while maintaining enhanced defect detection capabilities.
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 device detects abnormalities early and corrects them in real-time, significantly reducing the risk of modeling failures and enhancing production efficiency by allowing for continuous monitoring and adjustment during the manufacturing process.
Implementation Method 1
forming a sintered layer by emitting the light beam to a powder layer formed with the powders
Implementation Method 2
emitting a beam such as a light beam or an electronic beam to powders laid in layers
Implementation Method 3
measuring a roughness on the powder bed, a roughness or a temperature on a modeling surface formed by emitting the beam to the powder bed, or a temperature of the powder bed during emission of the beam
Data Source
AI summary
A three-dimensional additive manufacturing device is configured to emit a beam to a powder bed formed by laying a powder on a base plate to harden the powder bed selectively. A sensor is configured to detect the shape or the temperature of a surface of the powder bed or a modeling surface. A defect in laying of the powder or a defect in emission of the beam is corrected based on the detection result, before completion of forming of the next layer.