Build Layer Image Normalization for Additive Manufacturing Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Additive manufacturing apparatuses face challenges in accurately monitoring and controlling the build process due to variations in sensor data across the build plate, leading to potential errors and defects in the final product.
Innovation Solution
The method involves obtaining images of build layers using an imaging device, removing variations between features, and normalizing these features to eliminate location dependence, allowing for precise adjustments to the energy beam parameters during the additive manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors are used to monitor the build process, then measurement coverage is improved, but data processing complexity increases
Solution Approach 1:
The patent combines data from multiple sensors into a unified dataset that is processed together. The system integrates sensor readings across the build plate into comprehensive build layer images, allowing centralized processing that reduces overall system complexity while maintaining full measurement coverage.
Solution Approach 2:
The processing system is designed to handle multiple sensor types and data formats through a universal processing pipeline. The normalization and comparison operations can process data from any sensor location, making the system multi-functional without requiring separate processing paths for each sensor.
2Measurement precision
If multiple sensors are deployed across the build plate, then data coverage is improved, but data file sizes increase
Solution Approach 1:
The build plate is divided into discrete sensor zones, with each sensor monitoring a specific segment. The data from each segment is processed and compared independently against corresponding build layer images, allowing the system to handle large volumes of sensor data through segmented processing that reduces overall memory requirements.
Solution Approach 2:
The patent extracts only the essential features from sensor data that are relevant to build quality. By focusing on key parameters and comparing only critical features between build layers, the system reduces data file sizes while maintaining comprehensive coverage of the build plate.
3Reliability
If sensor data is processed in real-time, then error mitigation is improved, but processing speed requirements increase
Solution Approach 1:
The system performs preliminary processing of sensor data during the build process itself. Build layer images are captured and processed in real-time as each layer is created, allowing errors to be detected and corrected during manufacturing rather than requiring post-processing analysis, thus reducing the speed burden on the processing system.
Solution Approach 2:
The patent implements a feedback mechanism where sensor data from current build layers is immediately compared against reference images and used to adjust subsequent build parameters. This real-time feedback loop enables error mitigation by continuously guiding the build process based on actual measurements, improving reliability without requiring excessive processing speed.
Data Source
AI summary
An additive manufacturing apparatus, a computing system, and a method for operating an additive manufacturing apparatus are provided. The method includes obtaining two or more images corresponding to respective build layers at a build plate, wherein each image comprises a plurality of data points comprising a feature and corresponding location at the build plate; removing variation between the features of the plurality of data points; and normalizing each feature to remove location dependence in the plurality of data points.