Energy Beam Spot Verification Using Focus and Astigmatism Settings
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Solution Overview
Problem
Current methods for verifying the size and deflection speed of energy beams, such as laser or electron beams, in freeform fabrication are complex and require manual labor, lacking simplicity and efficiency.
Innovation Solution
A method involving varying focus and astigmatism lens settings to detect maximum intensity, comparing settings with stored values, and using cameras to verify beam spot size and deflection speed, which can be performed automatically and instantaneously without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual methods are used to verify beam spot size and deflection speed, then measurement precision can be achieved, but device complexity and loss of time increase
Solution Approach 1:
The system uses the energy beam itself to create verification patterns on the workpiece, and uses the workpiece surface as the measurement medium. The beam draws lines or patterns directly, and the camera captures these self-generated patterns for analysis, eliminating the need for separate calibration artifacts or complex measurement apparatus.
Solution Approach 2:
The patent replaces manual mechanical measurement methods with an automated optical detection system. A camera captures images of the beam-induced patterns, and image processing algorithms automatically calculate beam spot size and deflection speed, substituting human-operated mechanical measurement tools with automated vision-based measurement.
2Productivity
If automated verification methods are implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The verification system uses the same energy beam and workpiece configuration for both production and verification purposes. The beam operates in normal mode during fabrication, then switches to verification mode by drawing test patterns, eliminating the need for separate verification equipment and enabling multi-functionality of the existing system components.
Solution Approach 2:
The patent introduces a camera as an intermediary detection device that captures the beam's action on the workpiece. This intermediary translates the physical beam effects into visual data that can be processed by computer algorithms, enabling automated verification without requiring complex direct sensing of beam parameters.
3Reliability
If comprehensive verification at multiple positions and powers is performed, then reliability increases, but loss of time increases
Solution Approach 1:
The system performs verification at multiple beam powers and positions systematically, but the automated image capture and processing enable these comprehensive checks to be executed rapidly. The preliminary calibration data stored in memory allows for quick comparison against current measurements, reducing the time penalty of comprehensive verification.
Solution Approach 2:
The verification process is integrated into the normal operation workflow, allowing verification measurements to be taken continuously during or between production cycles. The automated system maintains continuous monitoring capability, and the beam can switch between production mode and verification mode without significant interruption to overall process continuity.
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 method provides a simple, fast, and automated verification of beam spot size and deflection speed, ensuring accurate calibration and minimizing equipment requirements, applicable to both laser and electron beams, and capable of detecting deviations to prevent quality issues in three-dimensional article manufacturing.
Implementation Method 1
varying a focus and/or astigmatism lens setting for the first energy beam spot until max intensity for the first beam spot is detected
Implementation Method 2
max intensity for the first beam spot is detected
Data Source
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AI summary
A method for verifying a size of an energy beam spot, said method comprising the steps of providing a first beam spot having a predetermined size and power at a first position on a work piece, varying a focus and/or astigmatism lens setting for said first beam spot until max intensity for the beam spot is detected, comparing the detected settings of said focus lens and/or astigmatism lens for said maximum intensity of the beam spot with stored settings of said focus lens and/or astigmatism lens for the beam spot with said predetermined size and power, repeating step a-c for different predetermined beam powers, repeating step a-d for different positions on said work piece, wherein said beam spot size is verified if each detected settings of said focus lens and/or astigmatism lens are deviating less than a predetermined value from corresponding stored settings of said focus lens and/or astigmatism lens.