Energy Beam Calibration Patterns for Thermal-Stable Alignment Detection
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Solution Overview
Problem
Existing determination devices for energy beams in additive manufacturing are cumbersome and time-consuming due to the need for thin wires that heat up and deform under irradiation, requiring skilled operators and extensive safety precautions.
Innovation Solution
A determination device with two determination units arranged in succession in the energy beam path, each comprising complementary pattern elements that generate a superordinate pattern when illuminated, allowing for improved calibration and reduced sensitivity to thermal effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If thin wires are used as determination units, then misalignment of the energy beam can be properly identified, but the wires heat up quickly and deform or melt under irradiation
Solution Approach 1:
The patent replaces the direct use of thin wires with solid determination units that have pattern elements. These pattern elements create optical patterns (shadows, diffraction patterns, or intensity distributions) that copy the information about beam alignment without requiring the determination units themselves to be thin and vulnerable to thermal effects.
Solution Approach 2:
The patent substitutes the mechanical/physical wire structure with an optical system using pattern elements. Instead of relying on the physical integrity of thin wires under thermal stress, the system uses optical interactions (shadow generation, diffraction, intensity modulation) to detect beam parameters, replacing a mechanical determination method with an optical one.
2Productivity
If thin wires are used for determination, then the determination process can be performed, but it requires skilled operators and must be completed quickly before wire deformation
Solution Approach 1:
The determination units with pattern elements automatically generate optical patterns that directly indicate beam alignment status. The system self-calibrates and provides visual feedback through the patterns formed by the pattern elements, eliminating the need for operator interpretation of wire shadow patterns and reducing dependency on operator skill and experience.
Solution Approach 2:
The patent utilizes changes in optical patterns (intensity distributions, shadow patterns, or diffraction patterns) generated by the pattern elements to indicate beam alignment. These visual pattern changes provide clear, unambiguous signals that are easier to interpret than wire shadow patterns, reducing the need for skilled operators to interpret subtle visual cues.
3Measurement precision
If wires are used as determination units, then beam alignment can be checked, but the operator must view the pattern on a screen requiring protective glasses and safety precautions
Solution Approach 1:
The pattern elements act as intermediaries between the energy beam and the observation system. They convert the beam parameters into optical patterns that can be observed without direct exposure to the high-energy beam. The pattern elements mediate the interaction, allowing alignment determination while eliminating the need for operators to view the direct beam or use protective housing.
4Measurement precision
If wires are used for determination, then calibration can be performed, but the position of the wire has small impact on intensity distribution making lateral position determination difficult
Solution Approach 1:
The pattern elements are designed with specific local structures (patterns, geometries, or configurations) that create pronounced local variations in the optical pattern when illuminated by the energy beam. These localized pattern features amplify the effect of beam position changes on the resulting optical distribution, making lateral position determination much more sensitive and precise compared to uniform wire structures.
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
The device enables more accurate and efficient determination of energy beam parameters with reduced operator dependency and safety concerns, as it uses solid pattern elements that are less affected by thermal effects and allow for automated calibration analysis.
Implementation Method 1
the shadow generated by illuminating the two wires with the energy beam
Implementation Method 2
the impact of the position of the wire on the intensity distribution of the energy beam
Data Source
AI summary
Determination device (2) for determining at least one parameter of an energy beam (4), in particular an energy beam (4) generated via an irradiation device of an apparatus (1) for additively manufacturing three-dimensional objects, which determination device (2) comprises two determination units (5, 6) arrangeable or arranged in succession in a beam path (3) of the energy beam (4), characterized in that each determination unit (5, 6) builds or comprises at least one complementary pattern element (15, 18, 21, 23, 24, 27, 30), wherein at least two pattern elements (15, 18, 21, 23, 24, 27, 30) of the two determination units (5, 6) complement each other to a superordinate pattern (32, 35).