Calibration Device for Multi-Laser 3D Printing Alignment
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Solution Overview
Problem
Existing calibration methods for three-dimensional object production using multiple radiation sources are complex and do not effectively improve production accuracy, particularly for apparatuses with dual or multiple laser systems.
Innovation Solution
A calibration device and method that iteratively determines the positions of individual laser beams to maximize output signals, allowing for detection and correction of deviations, thereby enhancing production accuracy by comparing actual and desired positions and calculating correction values for improved alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple radiation sources are used in the apparatus, then productivity is improved by processing larger areas simultaneously, but manufacturing precision deteriorates due to alignment deviations between multiple laser beams
Solution Approach 1:
The calibration device introduces a feedback mechanism by measuring the actual positions of multiple laser beams and comparing them with desired positions. The system calculates correction values based on measured deviations and feeds these corrections back to the control unit, which adjusts the deflection apparatus to eliminate alignment errors, thereby maintaining manufacturing precision while using multiple radiation sources
Solution Approach 2:
The patent replaces complex mechanical alignment mechanisms with an optical measurement and computational correction system. Instead of mechanically adjusting each laser source to perfect alignment, the system uses optical sensors to measure beam positions and computationally calculates correction values for the deflection apparatus, substituting mechanical precision requirements with optical measurement and software-based correction
2Manufacturing precision
If complex calibration methods using photosensitive film and alignment crosses are used, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the essential calibration function from complex mechanical alignment procedures and photosensitive film methods. The calibration device isolates the measurement task by using simple optical sensors to detect laser beam positions directly, eliminating the need for photosensitive film, alignment crosses, and manual measurement procedures, thereby reducing device complexity while maintaining precision
Solution Approach 2:
The calibration device creates an optical copy or representation of the laser beam positions by directing beams through pinholes onto a sensor array. This optical copying mechanism allows simultaneous measurement of multiple beam positions without physical contact or complex mechanical interfaces, simplifying the calibration procedure while achieving high precision
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
The calibration method significantly improves the production accuracy of three-dimensional objects by ensuring precise alignment of multiple laser beams, reducing production time and enhancing the ability to produce complex geometries with higher precision.
Implementation Method 1
two lasers 13a, 13b which each generate a laser beam 14a, 14b
Implementation Method 2
a sensor 32 arranged in said housing 31 which has an active surface 33 for receiving the laser beams 14a, 14b
Implementation Method 3
focused by a focusing apparatus 16a, 16b onto a predetermined point of the working plane 7
Data Source
AI summary
A calibration device (30) for an apparatus (1) for layerwise production of a three-dimensional object (2) by layerwise solidification of building material (10) at the locations corresponding to the cross section of the object to be produced in the respective layer by means of at least two energy beams (14a, 14b) includes a housing (31) and a sensor (32) which is arranged in the housing. The sensor serves to receive the at least two energy beams and to output an output signal as a function of the intensity of the energy beams. The housing has at least two through-openings (34a, 34b) for transmitting the at least two energy beams, which are arranged so that their central axes intersect on a surface of the sensor.