Additive Manufacturing Verification System for Build Geometry Correction
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Solution Overview
Problem
Current additive manufacturing (AM) devices lack a feedback loop for verifying and adjusting the build geometry of components, leading to inconsistencies and the need for manual adjustments by skilled operators.
Innovation Solution
A verification and adjustment system that uses multiple imaging devices and software to compare actual built components with 3D computer models, identifying geometric anomalies and automatically calibrating the AM device to prevent such anomalies in subsequent components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustments by skilled operators are used to correct build geometry inconsistencies, then manufacturing precision can be improved, but productivity decreases and device complexity increases
Solution Approach 1:
The patent implements an automated feedback loop where imaging devices capture images of the build platform during additive manufacturing, software compares actual geometry with the 3D computer model to detect anomalies, and the system automatically adjusts process parameters to correct deviations. This closed-loop feedback eliminates manual operator intervention while maintaining manufacturing precision and improving productivity.
Solution Approach 2:
The system enables the additive manufacturing device to self-correct build geometry anomalies through automated detection and adjustment. The imaging devices, software analysis, and automatic parameter modification work together to allow the system to verify and adjust its own build geometry without external manual intervention, thereby maintaining precision while accelerating production.
2Reliability
If multiple imaging devices and software verification systems are integrated into the AM device, then manufacturing precision and reliability improve, but device complexity increases
Solution Approach 1:
The imaging devices are integrated into the existing additive manufacturing device structure, serving dual purposes: capturing images for build geometry verification and potentially assisting in the additive manufacturing process itself. The software system performs multiple functions including image processing, anomaly detection, parameter analysis, and automatic adjustment control, consolidating verification and control functions into a unified system that manages complexity.
3Productivity
If automated verification and adjustment systems are implemented, then productivity improves by eliminating manual CAD file adjustments, but device complexity increases
Solution Approach 1:
The automated system establishes a real-time feedback mechanism where build geometry is continuously monitored during manufacturing, anomalies are detected and analyzed by software, and process parameters are automatically adjusted without requiring manual CAD file modifications. This automated feedback loop eliminates time-consuming manual interventions while streamlining the production workflow.
Solution Approach 2:
The system performs preliminary verification of build geometry during the manufacturing process itself, detecting and correcting anomalies before they propagate to subsequent layers or components. By conducting verification and adjustment actions in advance rather than requiring post-build manual CAD modifications, the system improves productivity while managing complexity through proactive rather than reactive control.
Data Source
AI summary
Verification and adjustment systems and methods correct at least one build error that is detected in a component built by additive manufacturing (hereinafter “AM”). The systems and methods comprise an AM device, a first imaging device, a second imaging device and computer-implement steps for correcting the build error present in the component. The first imaging device collects first digital images or data of the component and is positioned at a first orientation with respect to a build platform of the AM device. The second imaging device collects second digital images or data of the component and is positioned at a second orientation with respect to the build platform.