3D Printing Optics Calibration Using Beam Footprint Detection
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Solution Overview
Problem
Current 3D printing technologies face challenges in calibrating and maintaining the accuracy of energy beams used for forming three-dimensional objects, particularly in terms of location, speed, power density distribution, and focal point, which can lead to deviations in the optical system and affect detection speed and accuracy.
Innovation Solution
The system employs a calibration method using identifiable borders and a controller to direct the energy beam across calibration marks, measuring characteristics such as center position, power density distribution, and focal point, and adjusts these parameters to ensure accurate operation of the energy beam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If calibration marks and borders are used to calibrate energy beam characteristics, then manufacturing precision and measurement precision are improved, but device complexity increases due to additional calibration components and procedures
Solution Approach 1:
The patent uses optical copies and images of calibration marks rather than direct physical measurements. A detector captures an image of the calibration marks, and processing circuitry analyzes this optical copy to determine beam characteristics, replacing complex direct measurement systems with simpler optical imaging.
Solution Approach 2:
The patent replaces mechanical calibration procedures with optical and electronic systems. Instead of physically adjusting and measuring beam parameters through mechanical means, the system uses optical detection of calibration marks and electronic image processing to automatically determine beam characteristics.
2Manufacturing precision
If multiple calibration parameters (location, speed, power density distribution, focal point) are measured and adjusted, then manufacturing precision is improved, but measurement precision becomes more difficult to maintain due to increased calibration complexity
Solution Approach 1:
The calibration marks serve multiple functions simultaneously - they are used to calibrate beam location, speed, power density distribution, and focal point. This single multi-functional calibration structure replaces what would otherwise require multiple separate calibration systems and procedures.
Solution Approach 2:
The system creates optical copies of the calibration marks through the energy beam and uses image processing to extract multiple calibration parameters from these copies, simplifying the measurement of complex beam characteristics.
3Manufacturing precision
If the optical system is calibrated to maintain accurate energy beam properties, then manufacturing precision is improved, but loss of time occurs during calibration procedures
Solution Approach 1:
The calibration marks are pre-positioned on the build platform at known locations before the 3D printing process begins. This preliminary setup allows for rapid calibration during operation without requiring time-consuming adjustments or repositioning of components.
Solution Approach 2:
The system performs self-calibration by automatically detecting the positions of calibration marks and adjusting beam parameters based on detected deviations. This automated self-service calibration reduces the time and manual intervention required compared to traditional calibration methods.
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 precise calibration of energy beams, improving the accuracy and efficiency of the 3D printing process by maintaining the optical system's calibrated properties and enhancing detection speed and accuracy.
Implementation Method 1
irradiating an energy beam on a first calibration mark... the energy beam has a footprint which comprises a projection of the energy beam onto the shutter
Data Source
AI summary
The present disclosure provides various apparatuses, systems, software, and methods for three-dimensional (3D) printing. The disclosure delineates various optical components of the 3D printing system, their usage, and their optional calibration. The disclosure delineates calibration of one or more components of the 3D printer (e.g., the energy beam).