Additive Manufacturing Quality Estimation via Molding Surface Luminance
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Solution Overview
Problem
Current additive manufacturing systems require destructive or limited non-destructive inspections to detect internal defects in additive products, which hinder efficient production and quality control.
Innovation Solution
A quality estimation device that uses an imaging system to illuminate and image the molding surface during manufacturing, acquiring luminance data to estimate molding density and detect internal defects non-destructively, allowing for real-time quality assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If destructive inspection is performed to detect internal defects, then detection accuracy is improved, but the additive product is destroyed and cannot be shipped
Solution Approach 1:
The patent replaces physical contact-based destructive inspection methods with optical field-based imaging. The imaging device captures light reflected from the molding surface during additive manufacturing, and the control unit processes these optical signals to estimate molding density and detect internal defects without mechanical contact or destruction of the product.
Solution Approach 2:
The patent introduces light as an intermediary medium to probe internal defects. By illuminating the molding surface and analyzing reflected light patterns, the system indirectly detects internal defects through their effect on light reflection, avoiding direct contact that would destroy the product.
2Reliability
If non-destructive inspection by X-ray CT scanning is performed, then product usability is maintained, but the inspectable region is limited and requires separate test pieces
Solution Approach 1:
The patent transitions from limited 2D surface inspection or small-region 3D CT scanning to comprehensive full-surface inspection. By moving the imaging device to capture images across the entire molding surface during manufacturing, the system achieves complete coverage without restricting the inspectable area.
Solution Approach 2:
The patent performs inspection during the additive manufacturing process itself, before the product is completed and shipped. The imaging device captures molding surface information in real-time during layer formation, allowing defect detection to occur preliminarily during production rather than requiring separate post-manufacturing inspection steps.
3Productivity
If real-time quality assessment is implemented during manufacturing, then productivity is improved by preventing defective products, but device complexity increases
Solution Approach 1:
The imaging device serves multiple functions: it captures images of the molding surface for quality inspection, and the control unit processes these images to estimate molding density and detect internal defects. This multi-functional approach integrates inspection capabilities into the existing manufacturing system without requiring entirely separate specialized equipment.
Solution Approach 2:
The system establishes a feedback loop where the imaging device continuously monitors the molding surface during additive manufacturing, the control unit analyzes the captured images to assess quality in real-time, and this information can trigger alerts or process adjustments immediately, enabling continuous improvement and prevention of defective product formation.
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 non-destructive detection of internal defects, improving production efficiency by preventing defective products from being shipped and allowing for immediate correction of manufacturing issues.
Implementation Method 1
a luminance acquisition unit acquires a luminance obtained by quantifying a brightness of a light reflected by at least the molding surface of the region
Data Source
AI summary
A quality estimation device for an additive product includes an imaging device configured to illuminate a region including a molding surface during manufacturing of the additive product and image the region, when manufacturing the additive product at a molding position by irradiating with a light beam and a material powder melting and solidifying, a luminance acquisition unit acquires a luminance obtained by quantifying a brightness of a light reflected by at least the molding surface of the region in an image in which the imaging device images the region, and a molding density estimation unit estimates a molding density indicating a density of the material powder in a solidified state after melting based on the luminance of the molding surface acquired by the luminance acquisition unit. The material powder is supplied to the molding position.