In-Situ Workpiece Measurement in Additive Manufacturing

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Solution Overview

Problem

Additive manufacturing technologies face challenges in efficiently producing complex workpieces due to high manufacturing time, material costs, and the need for extensive quality testing, which often results in costly rejects and reduced manufacturing efficiency.

Innovation Solution

Integration of a workpiece measurement system into the additive manufacturing process that allows for real-time measurement of critical workpiece data during construction, enabling the detection of dimensional and material defects, and allowing for process adjustments or cancellation to prevent rejects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If additive manufacturing is used to produce complex workpieces, then design freedom and geometric complexity are improved, but manufacturing time and material costs increase

Engineering Contradiction:

Improvegeometric complexityVSAvoidmanufacturing time

Core Design Contradiction:

ShapeVSLoss of time

Solution Approach 1:

The patent implements real-time measurement and monitoring during the additive manufacturing process to detect defects early, enabling immediate process adjustments or cancellations before complete workpiece production, thereby reducing wasted manufacturing time on defective parts

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously measures critical workpiece data during construction and feeds this information back to control the manufacturing process, allowing dynamic adjustment of parameters to prevent defects and reduce rework

Inventive Principle:

Principle #23Feedback

2Shape

If additive manufacturing is used for complex workpieces, then design freedom is improved, but material costs and manufacturing expenses increase

Engineering Contradiction:

Improvegeometric complexityVSAvoidmaterial waste

Core Design Contradiction:

ShapeVSLoss of substance

Solution Approach 1:

Real-time measurement during construction enables early detection of defects, allowing process cancellation before complete material consumption, thereby reducing material waste on defective workpieces

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Continuous monitoring of critical workpiece data provides feedback to adjust manufacturing parameters in real-time, preventing defects that would lead to material waste and costly rejects

Inventive Principle:

Principle #23Feedback

3Measurement precision

If conventional quality testing is applied to additively manufactured workpieces, then detection capability is improved, but testing time and costs increase

Engineering Contradiction:

Improvedefect detection capabilityVSAvoidtesting time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The measurement system performs quality assessment during construction rather than after completion, enabling early defect detection and eliminating the need for separate post-manufacturing inspection time

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Real-time measurement data provides continuous feedback on workpiece quality, replacing conventional end-of-process inspection with ongoing monitoring that reduces total testing time

Inventive Principle:

Principle #23Feedback

4Productivity

If real-time measurement is implemented during additive manufacturing, then manufacturing efficiency is improved, but device complexity increases

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The measurement system is designed to perform multiple functions including dimensional measurement, defect detection, and process monitoring within a single integrated platform, reducing overall system complexity despite enhanced capabilities

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system uses an intermediary measurement device that bridges the additive manufacturing process and quality control, enabling real-time monitoring without directly modifying the core manufacturing equipment

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12202205B2Device and method for the additive manufacture of a workpiece

Publication Date: 2025.01.21 INTOM

AI summary

A device for additive manufacturing of a workpiece (10; 30) having a cell-like building space (24) for the workpiece to be built, preferably layer by layer, and an additive manufacturing unit (14; 34, 36) provided on or in the building space, wherein a workpiece measurement apparatus (16, 18, 20; 40, 42; 82, 86) is provided on or in the building space such that the workpiece measurement apparatus that provides the workpiece with irradiation from an irradiation source has a detector unit (22; 42) configured to detect an irradiation image of the workpiece provided with the irradiation on and/or through an outer wall of the workpiece, and/or to detect a nuclear spin image of the workpiece provided with the magnetic field excitation, and to generate workpiece measurement data from the irradiation image or the nuclear spin image.