Additive Manufacturing Beam Calibration for Consistent Solidification

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Solution Overview

Problem

Existing additive manufacturing systems, particularly for metal objects, face challenges in achieving high-quality production while maintaining a large manufacturing output.

Innovation Solution

The method and apparatus utilize two determining units to measure the characteristics of the electromagnetic radiation beam at different positions, allowing for calibration and control of the solidifying process to maintain consistent beam characteristics, thereby improving product quality while allowing for high output.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If beam characteristics are monitored at the solidification location to improve quality, then manufacturing precision improves, but productivity decreases due to process interruption

Engineering Contradiction:

Improvequality of manufactured objectVSAvoidmanufacturing output

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent uses a second determining unit to create a copy of the beam characteristic measurement at a displaced position that does not interrupt the solidification process. This allows continuous monitoring and calibration while maintaining productivity, as the measurement copy is taken from beam characteristics at a different location that doesn't interfere with the manufacturing process.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent introduces an intermediary measurement approach by measuring beam characteristics at a displaced position rather than directly at the solidification location. This intermediary measurement point allows the system to obtain beam characteristic data without the measurement process itself interfering with the manufacturing operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If beam characteristics are monitored continuously at the solidification location, then manufacturing precision improves, but device complexity increases

Engineering Contradiction:

Improveconsistency of solidification processVSAvoidcomplexity of measurement and control system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system creates a simplified copy of the measurement function at a displaced position using the second determining unit. This copy allows continuous monitoring without requiring complex real-time measurement systems at the solidification location itself, thereby reducing overall device complexity while maintaining precision.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent implements a feedback mechanism where beam characteristics measured at the displaced position are used to control the solidifying device. This feedback loop ensures consistent solidification quality without requiring direct real-time measurement at the critical location, simplifying the measurement system while maintaining control precision.

Inventive Principle:

Principle #23Feedback

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 approach enables the production of high-quality objects by compensating for variations in beam characteristics during manufacturing, ensuring a consistent solidification process and maintaining a high manufacturing output.

Implementation Method 1

a first determining unit for determining a characteristic of said beam of electromagnetic radiation at a first position of said beam of electromagnetic radiation

Methodology Applied

Scientific EffectElectromagnetic radiation detection:

Implementation Method 2

a second determining unit for determining said characteristic of said beam of electromagnetic radiation at a second position

Methodology Applied

Scientific EffectElectromagnetic radiation detection:

Implementation Method 3

a process chamber for receiving a bath of powdered material which can be solidified by exposure to electromagnetic radiation

Methodology Applied

Scientific EffectElectromagnetic radiation heating: Absorption (EM radiation)

Implementation Method 4

a control unit for calibrating said second determining unit taking into account said characteristic of said beam of electromagnetic radiation, determined by said first determining unit

Methodology Applied

Scientific EffectCalibration:

Data Source

PatentUS12496780B2Method and apparatus for producing an object by means of additive manufacturing

Publication Date: 2025.12.16 ADDITIVE IND

AI summary

Method for producing an object by additive manufacturing including the steps of determining, via a first determining unit, a characteristic of a beam of electromagnetic radiation at a first position of the beam and determining, via a second determining unit, the characteristic of the beam of electromagnetic radiation at a second position, and calibrating, via a control unit, the second determining unit according to the characteristic of the beam, determined by the first determining unit. An apparatus for manufacturing an object by additive manufacturing.