3D Additive Manufacturing Optical Path Redirection
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Solution Overview
Problem
In three-dimensional additive manufacturing, the detection accuracy of undulations in the build surface area is compromised due to the difficulty in providing separate or large window portions for projection and imaging parts, especially when multiple beam irradiation units are used, which disturbs airflow and limits space for window installation.
Innovation Solution
A three-dimensional additive manufacturing device with a projection part and imaging part disposed outside the chamber, and a reflective part inside the chamber to reflect light beams, allowing them to pass through a single window portion, thereby increasing the detection accuracy of undulations and maintaining airflow integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the projection part and imaging part are disposed outside the chamber, then the airflow is not disturbed and manufacturing quality is ensured, but the window portion size must be large enough to accommodate both optical paths, which reduces the available space for other components
Solution Approach 1:
The patent introduces a reflective part (mirror) to change the optical path direction. By reflecting the light beam from the projection part at an angle, the system can use a single window portion with optimized opening direction rather than requiring large separate openings for each optical path, thus resolving the space conflict while maintaining external placement of detection components.
2Productivity
If multiple beam irradiation devices are provided to shorten manufacturing time, then productivity increases, but the number of window portions required increases, making it difficult to provide separate window portions for projection and imaging parts
Solution Approach 1:
The patent designs a universal window portion configuration that can accommodate optical paths from multiple beam irradiation devices. By using a single window portion with appropriate opening directions and incorporating reflective parts to redirect light beams, the system enables multiple irradiation devices to share the same window infrastructure, reducing overall system complexity while maintaining high productivity.
3Device complexity
If the angle between optical axes of projection and imaging parts is small to fit through one window portion, then device complexity is reduced, but detection accuracy of undulation deteriorates
Solution Approach 1:
The patent uses a reflective part to change the spatial arrangement of optical paths. By reflecting the projection light beam at a specific angle, the system creates a larger effective angle between the projection and imaging optical axes while still using a single window portion. This resolves the contradiction by decoupling the window portion angle requirement from the actual detection angle, thereby maintaining both simplicity and accuracy.
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 configuration enhances the detection accuracy of undulations in the build surface area while minimizing the window size and maintaining airflow integrity, even with space limitations, by adjusting the light paths and angles to reduce distortion and improve optical resolution.
Implementation Method 1
a reflective part that is configured to reflect at least any one of a first light beam projected by the projection part or a second light beam captured by the imaging part
Data Source
AI summary
A three-dimensional additive manufacturing device, which performs additive manufacturing by irradiating, with a beam, a powder bed laid on a build surface area, includes a projection unit that is configured to project a pattern in which there is a luminance distribution in the build surface area and the luminance distribution changes over time, an imaging unit configured to image the pattern projected onto the build surface area, and a reflective part configured to reflect at least one among a first light beam projected by the projection unit and a second light beam captured by the imaging unit. The projection and imaging units are disposed outside the chamber where the additive manufacturing is performed on the build surface area. The reflective part is accommodated inside the chamber. The first and second light beams pass through one first window portion installed on the chamber.