Additive Manufacturing Calibration via Reference Standard Articles
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Solution Overview
Problem
Existing additive manufacturing (AM) methods lack effective evaluation processes to assess the accuracy and geometric reproducibility performance of AM machines over time, making it difficult to determine if components are formed within predetermined tolerances.
Innovation Solution
A system and method that utilize reference standard articles to evaluate the calibrated accuracy of AM machines by measuring Geometric Dimensioning & Tolerancing (GD&T) parameters, including straightness, circularity, and perpendicularity, using a computing device and evaluation devices like coordinate measuring machines or laser scanning machines to compare formed components against predetermined standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If additive manufacturing methods are used to form components rapidly and in situ, then productivity and response time are improved, but the ability to evaluate accuracy and geometric reproducibility deteriorates
Solution Approach 1:
The system performs preliminary actions by printing reference standard articles with known geometric characteristics before evaluating the AM machine's accuracy. These reference articles serve as calibration standards that enable subsequent measurement and evaluation of the machine's geometric reproducibility and accuracy over time
Solution Approach 2:
Reference standard articles act as intermediaries between the AM machine and the evaluation system. These articles contain known geometric features that bridge the gap between the manufactured components and the measurement device, enabling indirect evaluation of the AM machine's accuracy through comparison of measured features against reference values
2Measurement precision
If reference standard articles are printed and measured to evaluate AM machine accuracy, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The reference standard articles serve multiple functions: they act as calibration standards, measurement targets, and evaluation references simultaneously. The same printed reference articles are used to evaluate multiple different AM machines, making the evaluation system universally applicable across different manufacturing platforms without requiring machine-specific reference standards
Solution Approach 2:
The system creates simplified copies of reference standard articles using the AM machine itself, rather than requiring complex external measurement artifacts. These copied reference articles contain the essential geometric features needed for accuracy evaluation but are simpler to produce and measure than traditional calibration standards, reducing the overall complexity of the evaluation system
Data Source
AI summary
A system is configured to determine the calibration accuracy of an additive manufacturing machine for each of fourteen (14) geometric dimensioning and tolerancing parameters. The system also allows for the comparison of the calibration accuracy of multiple additive manufacturing machines.