Analyzer System for 3D Printer Beam Alignment
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Solution Overview
Problem
In three-dimensional printing systems that use an energy beam, maintaining accurate focus and alignment of the energy beam is challenging due to potential drift or misalignment during the manufacturing process.
Innovation Solution
The implementation of an analyzer system that includes an alignment component rotating with the build platform but inhibited from moving along with it, allowing the alignment component to remain at the focal plane and monitor the energy beam's focus and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the build platform rotates and moves along the platform movement axis during manufacturing, then the three-dimensional printing process can be completed, but the energy beam becomes out of focus and misaligned
Solution Approach 1:
The alignment component serves as an intermediary element between the build platform and the energy beam monitoring system. It rotates with the build platform but remains constrained to maintain a fixed position relative to the energy beam's focal plane, thereby mediating between the moving platform and the stationary beam path to enable continuous focus monitoring without interference from platform motion
Solution Approach 2:
The analyzer system provides real-time feedback about the energy beam's focal position by monitoring reflections or signals from the alignment component. This feedback loop allows the system to detect and correct focus drift caused by platform movement, enabling maintenance of manufacturing precision throughout the printing process
2Measurement precision
If an alignment component rotates with the build platform, then it can monitor the energy beam throughout the printing process, but it will move along with the platform and lose focal plane position
Solution Approach 1:
The alignment component acts as a mediator that decouples the rotational motion from the focal plane positioning. It is mechanically coupled to rotate with the build platform while simultaneously being constrained by the support bearing to maintain its position in the focal plane, thus enabling continuous monitoring without losing focus
Solution Approach 2:
The system separates the rotational function from the positioning function. The alignment component handles rotation with the platform while the support bearing handles positional constraint, dividing the combined motion control into independent functional segments that can operate without interfering with each other
Data Source
AI summary
A processing machine (10) for building an object (11) from a material (12) includes a build platform (16), a platform mover assembly (20), a material supply (22), an irradiation device (26), and an analyzer system (30). The platform mover assembly (20) moves the build platform (16) about a platform movement axis (48X) and along the platform movement axis (48X). The material supply (22) supplies material (12) to build the object (11) on the build platform (16). The irradiation device (26) irradiates at least a portion of the material (12) with an energy beam (26A) to form the object (11) from the material (12) on the build platform (16). The analyzer system (30) is configured to monitor the energy beam (26A). The analyzer system (30) includes an alignment component (36) that rotates concurrently with the build platform (16) about the platform movement axis (48X), but that is inhibited from moving concurrently with the build platform (16) along the platform movement axis (48X).