Additive Manufacturing Build Platform Calibration via Reflective Imaging
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Solution Overview
Problem
In additive manufacturing systems, improper positioning of the build platform can lead to reduced build quality and accuracy due to misalignment, resulting in structurally inferior components and decreased operational efficiency.
Innovation Solution
A calibration system comprising a reflective element, a camera, and a computing device is used to adjust the inclination of the movable build platform by comparing actual reflective images of a calibration model with predetermined images, ensuring accurate alignment and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the build platform is manually positioned without calibration, then the device complexity is reduced, but the manufacturing precision and build quality deteriorate due to misalignment and improper inclination
Solution Approach 1:
The patent replaces manual mechanical positioning and visual alignment methods with an automated optical measurement system. The camera captures images of the calibration model, and the computing device automatically calculates inclination angles and generates adjustment instructions, eliminating the need for manual measurement tools and expert operator judgment.
Solution Approach 2:
The calibration system enables the build platform to self-calibrate through an automated feedback loop. The system captures images, calculates inclination, generates adjustment instructions, and verifies calibration without requiring external intervention or manual measurement, making the calibration process autonomous and repeatable.
2Manufacturing precision
If the build platform inclination is not calibrated, then the ease of operation is improved, but the manufacturing precision deteriorates resulting in structurally inferior components
Solution Approach 1:
The system implements a feedback mechanism where the camera continuously monitors the calibration model on the build platform, the computing device calculates the actual inclination angles, compares them against target values, and generates adjustment instructions to eliminate deviations. This closed-loop feedback ensures accurate calibration while automating the process.
Solution Approach 2:
The calibration model serves as an intermediary object that translates the build platform's physical inclination into measurable image data. The camera captures the calibration model's position and orientation, which the computing device then converts into quantitative inclination measurements and adjustment instructions, bridging the gap between physical state and control actions.
3Manufacturing precision
If powder material is deposited on a misaligned build platform, then the productivity is maintained, but the manufacturing precision deteriorates due to shifted or dispersed powder material
Solution Approach 1:
The system performs calibration as a preliminary action before the actual build process begins. By capturing images of the calibration model, calculating inclination angles, and generating adjustment instructions in advance, the system ensures the build platform is properly positioned before powder material is deposited, preventing positioning errors without delaying production.
4Manufacturing precision
If the build platform is tilted or inclined, then the ease of operation is improved, but the manufacturing precision deteriorates due to reduced powder material layer thickness
Solution Approach 1:
The patent replaces manual tilt adjustment mechanisms with an automated measurement and control system. The camera and computing device precisely measure the build platform's inclination and generate quantitative adjustment instructions, eliminating the imprecision and subjectivity of manual mechanical adjustment while maintaining operational simplicity.
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
This solution ensures precise positioning of the build platform, improving the quality and accuracy of components built by maintaining consistent build quality across production environments and between builds.
Implementation Method 1
a first camera positioned above the reflective element and substantially aligned with the first calibration model, the first camera visually aligned with the reflective element to capture a first reflective image of the first calibration model as reflected by the reflective element
Data Source
AI summary
Additive manufacturing systems (AMS) are disclosed. The AMS may include a movable build platform, and a calibration system operably connected to the build platform. The calibration system may include a reflective element operably coupled to the build platform, a first calibration model positioned above and vertically offset from the reflective element, and a first camera substantially aligned with the first calibration model. The first camera may be visually aligned with the reflective element to capture a first reflective image of the first calibration model as reflected by the reflective element. The calibration system may also include at least one computing device operably connected to the build platform and the first camera, and configured to calibrate the build platform by: adjusting an actual inclination of the build platform in response to determining the first reflective image differs from a predetermined image of the first calibration model.