In-Process Dimensional Inspection for Additive Manufacturing Quality Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current additive manufacturing techniques face challenges in inspecting complex parts with enclosed surfaces, particularly in aerospace applications, where effective quality control of structural components is critical but difficult due to the complexity and enclosed nature of the parts.
Innovation Solution
The method involves sequentially forming layers of a part based on a geometric description while synchronously acquiring dimensional data, allowing for non-destructive, in-process inspection and comparison to ensure 100% verification of the additively manufactured parts, using a combination of deposition devices and dimensional measuring techniques within an integrated additive manufacturing apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If additive manufacturing is used to create complex parts without tooling, then manufacturing cost and material efficiency are improved, but inspection difficulty and quality control capability deteriorate
Solution Approach 1:
The patent applies preliminary action by performing inspection during the manufacturing process itself (in-process inspection) rather than after completion. The dimensional measuring device captures data at multiple stages of layer formation, enabling early detection of defects and continuous quality verification throughout additive manufacturing, thus resolving the inspection difficulty while maintaining cost efficiency
Solution Approach 2:
The patent implements nesting by integrating the dimensional measuring device within the additive manufacturing apparatus. The measuring device is positioned to inspect parts internally during manufacturing, allowing inspection functionality to be nested within the manufacturing system itself, thereby enabling comprehensive quality control of complex enclosed surfaces without external inspection equipment
2Difficulty of detecting and measuring
If traditional manufacturing techniques are used, then inspection capability is improved, but material efficiency and complexity handling deteriorate
Solution Approach 1:
The patent replaces traditional mechanical inspection methods with non-contact optical or electromagnetic dimensional measuring techniques. This substitution enables inspection of complex enclosed surfaces that would be inaccessible to mechanical probes, maintaining inspection capability while working within the additive manufacturing process to preserve material efficiency
Solution Approach 2:
The patent introduces an intermediary dimensional measuring device that acts as a mediator between the additive manufacturing process and quality control requirements. This intermediary captures dimensional data non-destructively during manufacturing, bridging the gap between additive manufacturing's material efficiency and the need for comprehensive inspection capability
Data Source
AI summary
Methods and apparatuses to fabricate additive manufactured parts with in-process monitoring are described. As parts are formed layer-by-layer, a 3D measurement of each layer or layer group may be acquired. The acquisition of dimensional data may be performed at least partially in parallel with the formation of layers. The dimensional data may be accumulated until the part is fully formed, resulting in a part that was completely inspected as it was built. The as-built measurement data may be compared to the input geometrical description of the desired part shape. Where the part fails to meet tolerance, it may be amended during the build process or rejected.