Calibration Plate Imaging for 3D Printing Laser Alignment
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Solution Overview
Problem
Existing powder bed fusion printing systems experience misalignment between planned and irradiated positions due to manufacturing tolerances and temperature changes, leading to reduced rigidity and dimensional inaccuracies in printed workpieces.
Innovation Solution
A calibration method using a calibration plate with reflective marks and an imaging system to capture images of these marks and laser spots, allowing for precise alignment and calibration of the printing system by comparing the positions of the marks and laser spots in different images.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the printing system operates without calibration, then the production process is faster and simpler, but the alignment between planned and irradiated positions deviates, leading to reduced manufacturing precision
Solution Approach 1:
The calibration plate is positioned in the build area before the actual printing process begins. The imaging system captures images of the calibration marks and laser spots in advance to determine transformation parameters. This preliminary calibration action ensures that subsequent printing operations use corrected position data, resolving the contradiction by preparing the system beforehand rather than during production.
Solution Approach 2:
The calibration plate creates a reference copy of the build area geometry with known mark positions. By comparing the captured images of calibration marks against their known positions, the system generates transformation parameters that copy and correct the coordinate system alignment. This copying approach enables precise alignment without requiring complex real-time measurement systems.
2Manufacturing precision
If calibration is performed using traditional methods, then some alignment correction is achieved, but the calibration accuracy is insufficient to meet tight manufacturing tolerances
Solution Approach 1:
The patent replaces traditional mechanical calibration methods with an optical-imaging-based system. The imaging system captures images of calibration marks and laser spots, and software automatically calculates transformation parameters. This substitution of mechanical adjustment with optical detection and computational analysis significantly improves calibration accuracy while maintaining efficient calibration time.
Solution Approach 2:
The calibration system is self-calibrating through automated image capture and processing. The imaging system automatically detects calibration mark positions, compares them with known positions, calculates transformation parameters, and applies corrections without requiring manual intervention. This self-service approach eliminates time-consuming manual calibration steps while achieving high precision.
3Reliability
If the build platform is rigidly fixed, then the system structure is simpler, but temperature changes and manufacturing tolerances cause misalignment that cannot be compensated
Solution Approach 1:
The imaging system provides feedback on the actual positions of calibration marks and laser spots. By comparing captured images with expected positions, the system determines transformation parameters that compensate for misalignments caused by temperature changes and manufacturing tolerances. This feedback mechanism enables the rigid build platform to maintain reliability by correcting position deviations through software rather than requiring complex mechanical adjustments.
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 method enables efficient and accurate calibration of the printing system, reducing misalignment and ensuring precise production of three-dimensional workpieces within acceptable manufacturing tolerances.
Implementation Method 1
A calibration method using a calibration plate with reflective marks and an imaging system to capture images of these marks and laser spots
Implementation Method 2
controlling an irradiation system to irradiate, with a laser beam, a point on the calibration plate
Data Source
AI summary
A calibration method for a printing system configured to produce a three-dimensional workpiece is provided. A first image of a first portion of a calibration plate is obtained, a position of at least a part of a calibration mark of the calibration plate is detected in the first image, an irradiation system of the printing system irradiates, with a laser beam, a point on the first portion of the calibration plate, a second image of the first portion is obtained, a position of a spot of light formed by the laser beam is detected in the second image, and the printing system is calibrated based on the detected position of the at least one part in the first image and the detected position of the spot of light in the second image. A corresponding printing system is also provided.