Additive Manufacturing Sensor Calibration via Spectral Beam Splitting
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Solution Overview
Problem
Current additive manufacturing (AM) processes face challenges in achieving high-resolution, large field of view, and fast data rate monitoring, leading to difficulties in calibrating sensor data with process physics for characterizing AM part quality due to mismatched spatial and temporal resolutions, and fidelity issues with existing sensors.
Innovation Solution
A system comprising an additive manufacturing machine, an optics assembly, and multiple sensors of different configurations, where the optics assembly splits electromagnetic radiation into multiple beams for simultaneous monitoring and calibration, allowing for high-resolution data collection across a large field of view while maintaining a predetermined relationship between the build point and field of view.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high-resolution sensors (photodiodes or pyrometers) are used, then measurement precision and data rate are improved, but field of view is restricted
Solution Approach 1:
The system segments the electromagnetic radiation from the build region into multiple spectral beams using an optics assembly with dichroic mirrors and filters. Each sensor receives a specific spectral band, allowing high-resolution measurement across different wavelengths simultaneously. This segmentation enables both high measurement precision and expanded effective field of view by combining multiple spectral channels.
2Area of stationary object
If large field of view camera systems are used, then field of view is improved, but data rate and resolution are reduced due to vast data volume
Solution Approach 1:
The system applies local quality by assigning different spectral resolution characteristics to different spatial regions and sensors. The optics assembly directs specific spectral bands to specialized sensors that can process data at high rates. This allows the system to maintain high measurement precision in critical regions while covering a large overall field of view, avoiding the data bottleneck of uniform high-resolution imaging across the entire view.
3Area of stationary object
If multiple sensors are used to achieve both high resolution and large field of view, then measurement precision and field of view are improved, but device complexity and calibration difficulty increase
Solution Approach 1:
The system merges multiple sensing functions into a unified optical measurement system. The optics assembly combines multiple spectral beams from the same build region onto different sensors, creating a coordinated multi-spectral measurement system. This merging approach synchronizes data collection across sensors and reduces calibration complexity compared to using independent sensors, while achieving both high resolution and large field of view through spectral diversity.
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 solution enables repeatable calibration and synchronization of in situ process-monitoring sensors, improving the fidelity and accuracy of AM part quality characterization by integrating multi-scale monitoring and calibration methods.
Implementation Method 1
an optics assembly, a first sensor, a second sensor of a different configuration from the first sensor, and a controller. The additive manufacturing machine is configured to selectively scan a build beam across a region of interest to thereby add material to a workpiece at a moving build point located in the region of interest. The optics assembly is configured to separate electromagnetic radiation emitted from the region of interest into a first beam and a second beam
Data Source
AI summary
An exemplary system generally includes an additive manufacturing machine, an optics assembly, a first sensor, a second sensor of a different configuration from the first sensor, and a controller. The additive manufacturing machine is configured to selectively scan a build beam across a region of interest to thereby add material to a workpiece at a moving build point located in the region of interest. The optics assembly is configured to separate electromagnetic radiation emitted from the region of interest into a first beam and a second beam. The first sensor is configured to receive the first beam and to generate first information related to the first beam. The second sensor is configured to receive the second beam and to generate second information related to the second beam. The controller is configured to calibrate the second sensor based upon the first information and the second information.