Additive Manufacturing Inline Monitoring via Deflection Unit
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Solution Overview
Problem
Current additive manufacturing processes lack effective inline monitoring and control, leading to defects in components being discovered only after completion, resulting in wasted time and material.
Innovation Solution
A method and device that enable the freely controllable, location-selective inline acquisition of information from the vicinity of the processing radiation interaction zone by using a deflection unit to position a measuring zone independently of the processing zone, allowing for real-time observation and correction of defects during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a coaxial process sensor system is used for inline detection, then real-time monitoring of the processing area is enabled, but the measurement field is fixed relative to the processing area and cannot observe the built-up solid
Solution Approach 1:
The patent applies the dynamics principle by making the measurement field movable relative to the processing area. The independent positioning system allows the measurement field to be dynamically adjusted to different locations on the built-up solid, transforming the fixed coaxial arrangement into a flexible, adaptable measurement system that can observe various regions during and after processing.
2Reliability
If inline process control is implemented, then defects can be detected during manufacturing, but additional monitoring equipment and complexity are required
Solution Approach 1:
The patent applies the universality principle by designing a monitoring system that serves multiple functions: it can measure both in the processing area and on the built-up solid, support various measurement techniques, and provide both real-time monitoring and post-processing inspection. This multi-functional approach consolidates what would otherwise require separate systems into a single versatile platform.
Solution Approach 2:
The patent uses an independent positioning system as an intermediary between the fixed processing optics and the measurement field. This intermediary component enables flexible positioning of the measurement field without requiring complex reconfiguration of the entire optical system, thereby managing complexity while achieving versatile inline monitoring.
3Productivity
If the measurement field is centered on the processing area, then real-time processing monitoring is achieved, but no information about the built-up solid can be obtained
Solution Approach 1:
The patent applies segmentation by separating the measurement function from the processing location. Instead of tying the measurement field to the processing area, the system divides the monitoring capability into independent measurement fields that can be positioned anywhere on the built-up solid, allowing simultaneous or sequential monitoring of both processing and previously built regions.
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 prompt detection and correction of defects, reducing material waste and production time by allowing for inline process control and optimization, thereby improving the quality and efficiency of the additive manufacturing process.
Implementation Method 1
a layer of a building material is locally solidified on a current processing surface of a component in the manufacturing process by means of processing with radiation
Implementation Method 2
Other known methods use the physical processes of melting and solidifying to produce the three-dimensional components. Of particular interest here are the laser sintering and laser melting processes
Implementation Method 3
outgoing radiation from the layer of construction material using the processing optics before adding a next layer of construction material is supplied to a detection and evaluation device and is recorded and evaluated by it
Data Source
Figure 1
Figure 2a~2c
Figure 3a~3d
AI summary
The invention relates to a method for the additive manufacture of components by locally consolidating a layer of a construction material on a current processing surface of a component that is in the production process by means of processing with radiation, wherein a processing beam (1) is focused at a processing zone (8) in the layer of the construction material by means of a processing optical system (6, 6', 7), relative motion between radiation exiting from the processing optical system (6, 6', 7) and the current processing surface of the component is performed by means of a motion device (7) in such a way that the processing zone (8) is guided along a predefined trajectory over the current processing surface of the component, and furthermore at least one input beam (12) used for process monitoring is coupled into the processing optical system (6, 6', 7), and output radiation coming from the layer of the construction material is fed to a detection and evaluation device by means of the processing optical system (6, 6', 7) before a next layer of the construction material is added and said output radiation is sensed and evaluated by said detection and evaluation device, wherein the at least one input beam (12) additionally passes a deflection unit (16) associated therewith such that the input beam is focused at a measurement zone (17) by means of the processing optical system (6, 6', 7), which measurement zone can be freely positioned on the current processing surface of the component relative to the processing zone (8) within a radius from the processing zone (8). The invention further relates to a device for carrying out the method.