Build Plane Thermal Energy Density Mapping for Additive Manufacturing
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Solution Overview
Problem
Current additive manufacturing processes lack effective non-destructive methods for verifying the mechanical, geometrical, and metallurgical properties of production parts, as conventional quality assurance testing often requires destructive testing, which is not applicable to production parts.
Innovation Solution
The implementation of optical sensing techniques to track in-process physical phenomena and determine thermal energy density (TED) during additive manufacturing, using sensors that monitor energy radiated from the build plane, allowing for real-time quality inference and process control by adjusting energy source parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional quality assurance testing is used to verify part properties, then measurement accuracy is improved, but the part is destroyed
Solution Approach 1:
The patent replaces mechanical/physical contact-based destructive testing with optical sensing that detects thermal radiation emitted during the additive manufacturing process. Optical sensors measure thermal energy density without contacting the part, enabling non-destructive quality assessment while maintaining measurement accuracy through thermal radiation detection.
Solution Approach 2:
The patent introduces thermal radiation as an intermediary carrier of quality information. Instead of directly measuring mechanical properties that would require destroying the part, the system measures thermal radiation emitted during manufacturing, which serves as an indirect but accurate indicator of part quality and process parameters.
2Reliability
If optical sensing is used to monitor thermal energy density, then non-destructive quality assessment is enabled, but device complexity increases
Solution Approach 1:
The patent implements a feedback system where optical sensors continuously monitor thermal energy density during additive manufacturing, and the data is fed back to adjust process parameters in real-time. This closed-loop control enables non-destructive quality assessment while automating the complexity of the sensing system, reducing the need for manual intervention and complex post-processing.
3Manufacturing precision
If real-time process control is implemented through optical sensing, then manufacturing precision is improved, but loss of time in data processing increases
Solution Approach 1:
The patent performs preliminary actions by establishing baseline thermal energy density ranges for quality parts before production begins. During manufacturing, the system only needs to compare real-time sensor data against these pre-established baselines, enabling rapid decision-making and real-time process control without extensive data processing delays.
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
Enables non-destructive quality assessment and process control, reducing discontinuities in the melt pool size and temperature variations, thereby improving the consistency and quality of additive manufactured parts.
Implementation Method 1
measuring an amount of energy radiated from the build plane during each of the plurality of scans using an optical sensor monitoring the build plane
Data Source
AI summary
This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensor; determining an area of the build plane traversed during the scans; determining a thermal energy density for the area of the build plane traversed by the scans based upon the amount of energy radiated and the area of the build plane traversed by the scans; mapping the thermal energy density to one or more location of the build plane; determining that the thermal energy density is characterized by a density outside a range of density values; and thereafter, adjusting subsequent scans of the energy source across or proximate the one or more locations of the build plane.