Beam Scan Field Calibration Using Camera Feedback in 3D Printing
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Solution Overview
Problem
Existing additive manufacturing machines require manual calibration of energy beams, which is time-consuming and prone to errors, consuming an entire day for proper alignment.
Innovation Solution
An automated method using a calibrated camera or melt pool emissions sensor to calibrate and adjust beam scan fields, allowing for automated commands from an electronic controller to direct, collect, generate, compare, and adjust the beam steering mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration processes are used, then operators can perform beam alignment, but the process consumes an entire day and is prone to errors
Solution Approach 1:
The patent replaces manual mechanical calibration operations with an automated optical measurement system. A camera captures images of calibration artifacts, and software automatically processes these images to determine beam scan field parameters, eliminating the need for manual measurement and alignment operations that consume entire days.
Solution Approach 2:
The patent uses calibrated artifacts with known geometries as reference copies. By capturing images of these standardized artifacts and comparing them against digital models, the system creates a digital replica of the physical calibration process, enabling automated measurement and alignment verification without manual intervention.
2Reliability
If manual calibration processes are used, then beam alignment can be performed, but the process is prone to human errors
Solution Approach 1:
The calibration system performs self-verification by automatically capturing images of calibration artifacts, processing the images through algorithms, and adjusting beam parameters based on measured deviations. The system serves itself by eliminating the need for external manual verification, thereby improving reliability while maintaining operational simplicity through automated workflows.
Solution Approach 2:
The patent implements a closed-loop feedback system where the camera continuously monitors calibration artifacts, measures actual beam positions against target positions, and automatically adjusts beam scan field parameters. This real-time feedback mechanism eliminates human error by replacing manual judgment with automated measurement and correction cycles.
3Productivity
If automated calibration using camera and sensors is implemented, then calibration time is significantly reduced, but the device complexity increases
Solution Approach 1:
The patent employs a multi-functional calibration system where a single camera setup serves multiple purposes: capturing calibration artifact images, measuring beam positions, verifying scan field geometry, and providing feedback for automated adjustment. This universal approach consolidates multiple calibration functions into one integrated system, reducing overall complexity despite the automated capabilities.
Solution Approach 2:
The patent introduces calibrated artifacts as intermediary objects that mediate between the beam system and the measurement system. These artifacts with known geometries serve as reference standards that the camera can measure, translating complex beam parameters into simple image-based measurements, thereby simplifying the overall measurement system while enabling high-speed automated calibration.
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 automated process significantly reduces calibration time, enhances precision, and ensures consistent results by eliminating manual errors, thereby improving the efficiency and quality of additive manufacturing.
Implementation Method 1
a radiant energy beam is used to selectively melt material to form a workpiece
Implementation Method 2
using a calibrated camera, collecting an image of the calibration build job
Implementation Method 3
using one or more emissions sensors, monitoring emissions from the melt pools
Data Source
AI summary
A method of calibrating a beam scan field of an additive manufacturing machine in which a radiant energy beam is used to selectively melt material to form a workpiece, the method including: using a radiant energy source, directing a beam using a steering mechanism so as to create a calibration build job on a substrate, the calibration build job including at least one measurement artifact created by the beam; using a calibrated camera, collecting an image of the calibration build job; generating a set of measurements of the calibration build job from the image; comparing the measurements to a standard; in response to the measurements deviating from the standard by more than a predetermined acceptable tolerance, adjusting the steering mechanism; wherein the steps of directing, collecting, generating, comparing, and adjusting are carried out in response to automated commands from an electronic controller.