3D Printing Beam Reflection Alignment for Layer Accuracy

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Solution Overview

Problem

Existing additive manufacturing processes face challenges in accurately determining and aligning the position of previously manufactured parts within the apparatus, leading to misalignment of irradiation patterns and object imperfections due to manual and time-consuming calibration processes.

Innovation Solution

An apparatus equipped with a position determination device that uses a measurement beam to detect the reflection of an energy beam off the object's surface, allowing for precise determination of the object's position, and generates a map to align the irradiation pattern accurately.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual determination and alignment of object position is used, then the apparatus can determine position data of manufactured parts, but the process is time-consuming and cumbersome

Engineering Contradiction:

Improveposition data determinationVSAvoidcalibration process time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical alignment operations with an automated optical measurement system. A measurement beam (laser) automatically scans the object surface to detect position data, eliminating the need for manual determination and alignment by operators. This substitution of mechanical/manual processes with automated optical measurement directly resolves the contradiction between measurement precision and time consumption.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If manual alignment of previously manufactured parts is performed, then position verification can be achieved, but operator intervention is required making the process cumbersome

Engineering Contradiction:

Improveposition verificationVSAvoidoperator intervention requirement

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The measurement system performs self-verification of object position without requiring operator intervention. The automated beam scanning and position detection system independently determines and verifies position data, making the system self-sufficient. This eliminates the need for operators to manually verify positions, thereby improving ease of operation while maintaining reliability through automated verification.

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If the object position deviates from nominal position, then manufacturing flexibility is maintained, but irradiation pattern misalignment occurs causing object imperfections

Engineering Contradiction:

Improveposition deviation toleranceVSAvoidirradiation pattern alignment

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The system uses feedback from the measurement beam to detect actual object position and automatically adjusts the irradiation pattern positioning accordingly. The measured position data feeds back to the control system, which compensates for deviations by adjusting the irradiation beam position. This closed-loop feedback mechanism maintains manufacturing precision even when objects have position deviations, resolving the contradiction between adaptability and 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

Facilitates rapid and precise alignment of objects by automating the position determination process, reducing time and effort, and ensuring accurate consolidation of build material layers.

Implementation Method 1

a position determination device which is adapted to determine position data relating to a position of at least one part of at least one object based on a detection of a reflected part of the energy beam or a reflected part of a measurement beam that is reflected at the at least one part of the at least one object

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

successive layerwise selective irradiation and consolidation of layers of a build material which can be consolidated by means of an energy source

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 3

a selective laser sintering apparatus, a selective laser melting apparatus or a selective electron beam melting apparatus

Methodology Applied

Scientific EffectSelective laser sintering: Selective Laser Sintering

Implementation Method 4

a selective electron beam melting apparatus

Methodology Applied

Scientific EffectElectron beam melting: Electron Beam

Data Source

PatentUS20250340010A1Apparatus for additively manufacturing three-dimensional objects

Publication Date: 2025.11.06 CONCEPT LASER

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 source, wherein a position determination device is provided that is adapted to determine position data relating to a position of at least one part of at least one object based on a detection of a reflected part of an energy beam or a measurement beam that is reflected at the at least one part of the at least one object.