Additive Manufacturing Position Calibration
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Solution Overview
Problem
Existing additive manufacturing methods face challenges in accurately determining and compensating for deviations in the x- and y-positions of the carrying element, which can lead to misalignment and offset in the layers of three-dimensional objects being built, affecting the precision and quality of the final product.
Innovation Solution
A method that determines the x- and y-positions of the carrying element for various z-positions, generating calibration data to adjust the irradiation device and compensate for deviations, ensuring precise positioning and alignment of the build material layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If only z-position monitoring is implemented, then the system complexity is reduced, but the positioning accuracy in x- and y-directions deteriorates
Solution Approach 1:
The patent applies preliminary action by determining the x- and y-positions of the carrying element in advance for various z-positions before the actual additive manufacturing process. This pre-calibration creates a lookup table or calibration data that enables real-time position compensation without adding complex real-time measurement systems, thus resolving the contradiction between system complexity and positioning accuracy.
2Manufacturing precision
If x- and y-position determination for multiple z-positions is implemented, then the manufacturing precision is improved, but the measurement and calibration time increases
Solution Approach 1:
The calibration process is performed in advance before production, separating the time-consuming measurement process from the actual manufacturing. The calibration data obtained beforehand is stored and reused for multiple manufacturing cycles, thus improving alignment precision without significantly impacting production time.
Solution Approach 2:
The patent uses optical copying or imaging methods to determine the positions of the carrying element. By creating optical images or patterns that represent the physical positions, the system can quickly capture and process position information without requiring physical measurement for each z-position, thereby reducing calibration time while maintaining precision.
3Measurement precision
If optical or mechanical determination methods are used, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The patent introduces an intermediary calibration process that mediates between the simple z-position monitoring system and the requirement for accurate x- and y-position determination. The calibration data acts as an intermediary layer that translates simple z-position measurements into accurate three-dimensional position information, achieving high measurement precision without requiring complex real-time determination systems.
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 approach enhances the positioning accuracy of the carrying element, allowing for improved alignment and quality of the three-dimensional objects by directly relating the x- and y-positions to the z-positions, thereby compensating for any deviations and ensuring precise irradiation patterns.
Implementation Method 1
additively manufacturing three-dimensional objects by means of successive layerwise selective consolidation of layers of a build material... which build material can be consolidated by means of an energy source
Implementation Method 2
energy source, such as an energy beam, e.g. an electron beam or a laser beam, is used to selectively layerwise irradiate and consolidate layers of build material
Data Source
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Figure 2
AI summary
Method for determining position data for an apparatus (1) for additively manufacturing three-dimensional objects (2) by means of successive layerwise selective consolidation of layers (17 - 19, 21 - 23) of a build material (3) arranged in a build plane (4) essentially extending in x- and y-direction, which build material (3) can be consolidated by means of an energy source, wherein the build material (3) is carried by a carrying element (9) of a carrying unit (8), wherein the carrying element (9) is essentially movable in z-direction, wherein the z-direction is essentially perpendicular to the x- and y-direction, wherein position data relating to an x- and/or y-position of the carrying element (9) are determined for at least one z-position.