Additive Manufacturing Beam Calibration for Thermal Drift Correction
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Solution Overview
Problem
Existing additive manufacturing technologies face challenges in maintaining accurate irradiation parameters due to thermal elongation and other effects during the process, leading to deviations in energy beam positioning and focal length, which cannot be automatically calibrated in real-time.
Innovation Solution
An apparatus with a calibration device comprising a positioning unit, determination unit, and calibration unit that reflects the energy beam to determine and adjust the irradiation device's position and orientation, ensuring proper spatial and focal alignment, allowing for automated calibration during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the irradiation device operates during the additive manufacturing process, then productivity is maintained, but the irradiation parameters deviate from nominal values due to thermal elongation and other effects
Solution Approach 1:
The patent implements a feedback mechanism where a determination unit continuously monitors the actual irradiation parameters (focal position, spot position) during the additive manufacturing process. Based on this real-time feedback, a positioning unit automatically adjusts the irradiation device to compensate for deviations caused by thermal elongation, enabling continuous operation while maintaining parameter accuracy.
Solution Approach 2:
The system performs self-calibration during the manufacturing process without requiring external intervention or stopping production. The determination unit detects parameter deviations and the positioning unit automatically corrects them, allowing the irradiation device to self-adjust and maintain nominal parameters throughout the manufacturing process.
2Measurement precision
If the irradiation device is calibrated in advance using a test specimen, then initial positioning accuracy is achieved, but the calibration cannot be updated during the manufacturing process to compensate for thermal effects
Solution Approach 1:
The patent transforms the static calibration process into a dynamic, continuous adjustment system. Instead of a fixed calibration performed once before manufacturing, the determination unit continuously measures actual irradiation parameters and the positioning unit dynamically adjusts the device throughout the manufacturing process to adapt to changing thermal conditions.
Solution Approach 2:
A real-time feedback loop is established where the determination unit monitors irradiation parameters during manufacturing and feeds this information back to the positioning unit, which automatically adjusts the device to maintain nominal parameters, enabling the system to adapt to thermal effects that occur during operation.
3Manufacturing precision
If the focal position or spatial position is determined and the irradiation device is calibrated in advance, then proper irradiation parameters can be achieved, but automatic calibration during the additive manufacturing process is not possible
Solution Approach 1:
The system performs automatic self-calibration during the additive manufacturing process without requiring external intervention. The determination unit automatically detects parameter deviations and the positioning unit automatically corrects them, enabling the device to maintain nominal irradiation parameters throughout manufacturing without stopping production or requiring manual recalibration.
Solution Approach 2:
An automatic feedback mechanism is implemented where the determination unit continuously monitors irradiation parameters and feeds this information to the positioning unit, which automatically adjusts the device to compensate for thermal effects, enabling in-process calibration without manual intervention.
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
Enables precise and automated calibration of the irradiation device, ensuring consistent energy deposition and improving the quality of three-dimensional objects by maintaining nominal irradiation parameters, even during ongoing additive manufacturing processes.
Implementation Method 1
a calibration unit (10) which is adapted to at least partially reflect the energy beam (5), wherein the irradiation device (6) is adapted to guide the energy beam (5) to the calibration unit (10) for generating a reflected part (12) of the energy beam (5)
Data Source
AI summary
Apparatus for additively manufacturing three-dimensional objects by means of successive layerwise selective irradiation and consolidation of layers of a build material which can be consolidated by means of an energy beam, which apparatus comprises an irradiation device adapted to guide an energy beam across a build plane, wherein a calibration device is provided comprising a positioning unit, a determination unit and a calibration unit, preferably arranged in a process chamber of the apparatus, that is adapted to at least partially reflect the energy beam, wherein the irradiation device is adapted to guide the energy beam to the calibration unit for generating a reflected part of the energy beam, wherein the positioning unit is adapted to position the irradiation device dependent on at least one parameter of the reflected part of the energy beam determined via the determination unit.