Powder Stream Imaging for Blown Additive Manufacturing Control

The patent introduces an illumination device as an intermediary element that enables the imaging device to visualize and measure the powder stream. The illumination device emits light that scatters off powder particles, creating a visible pathway that the imaging device can capture. This intermediary approach allows indirect measurement of powder flow characteristics without direct contact with the high-velocity powder stream, resolving the contradiction between measurement precision and system complexity.

The patent replaces direct mechanical measurement methods with an optical measurement system. Instead of using physical probes or sensors that would directly interact with the powder stream, the system uses illumination and imaging devices to optically detect powder flow characteristics. This substitution eliminates the need for complex mechanical measurement apparatus while achieving precise measurement of powder stream parameters.

The patent implements periodic monitoring of the powder stream rather than continuous monitoring. The illumination device and imaging device operate at specific intervals or trigger events, capturing powder stream characteristics at key moments during the additive manufacturing process. This periodic action maintains manufacturing precision by providing sufficient measurement data while significantly reducing energy consumption compared to continuous operation.

The patent applies partial monitoring action by focusing illumination and imaging resources on critical regions of the powder stream or critical time periods during powder delivery. Rather than monitoring the entire powder stream continuously, the system selectively monitors portions or phases of the powder delivery process that are most critical for manufacturing precision, thereby reducing overall energy consumption while maintaining adequate control.