Additive Manufacturing Supervision Using Offline Irradiation Data
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Solution Overview
Problem
Current additive manufacturing processes lack effective offline supervision methods for quality assessment, relying on real-time melt pool monitoring and optical tomography, which are limited in scope and resource-intensive, and do not allow for prior evaluation of manufacturing strategies.
Innovation Solution
A method and apparatus that generate a process chamber supervisory data set from irradiation control data, encoding information point-by-point to enable offline quality analysis, allowing for pre-, during-, or post-manufacturing evaluation of manufacturing processes, and integration with existing monitoring systems like melt pool monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If real-time melt pool monitoring and optical tomography are used for quality assessment, then measurement precision is improved, but device complexity and computational load increase
Solution Approach 1:
The patent generates a supervisory data set from irradiation control data before the additive manufacturing process begins, enabling pre-manufacturing quality assessment. This preliminary action allows quality evaluation without requiring complex real-time monitoring equipment during the actual manufacturing process, thereby reducing device complexity while maintaining measurement precision through offline analysis.
2Measurement precision
If comprehensive real-time monitoring is implemented during manufacturing, then quality data accuracy is improved, but productivity is reduced due to increased computational load
Solution Approach 1:
The supervisory data set is generated in advance from irradiation control data before the additive manufacturing process starts. This shifts the computational load to a pre-processing stage, allowing comprehensive quality analysis to be performed offline without interfering with real-time manufacturing operations, thus maintaining both quality data accuracy and manufacturing productivity.
3Manufacturing precision
If spatially resolved sensor data is collected during manufacturing, then manufacturing precision is improved, but loss of time increases due to extensive data processing
Solution Approach 1:
The patent performs spatially resolved quality analysis on the supervisory data set before manufacturing begins, identifying potential quality issues and optimizing process parameters in advance. This preliminary quality assessment eliminates the need for extensive real-time data processing during manufacturing, reducing time loss while maintaining manufacturing precision through pre-identified quality metrics.
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 comprehensive, resource-efficient quality data generation and process optimization, allowing for improved precision, reduced computational load during manufacturing, and enhanced identification of defects through spatially resolved analysis.
Implementation Method 1
selective solidification of the build-up material, wherein this solidification can be performed in many manufacturing processes with the aid of an irradiation with radiation energy, for example electromagnetic radiation, in particular light and/or heat radiation, but also with particle radiation, for example electron radiation
Implementation Method 2
by partially or completely melting the powder grains of the build-up material with the aid of the energy introduced locally at these points by the radiation
Implementation Method 3
to detect the melt pool created by the energy input. This is also referred to as 'melt pool monitoring'. The detected signal is dependent here on the radiation emitted or reflected by the melt pool
Data Source
AI summary
Disclosed is a method for supervision of an additive manufacturing process for producing a manufacturing product by selectively solidifying build-up material in a process chamber. The build-up material is irradiated according to predefinable irradiation control data; and a process chamber supervisory data set is generated based on the irradiation control data, supervisory data being encoded process chamber point by process chamber point in said data set. Quality data concerning the manufacturing process are determined based on the process chamber supervisory data set. A description is further given of a supervisory device suitable therefor a control device for an apparatus for additive manufacturing of manufacturing products, and an apparatus for additive manufacturing of manufacturing products comprising such a control device.