External Calibration Imaging for Additive Manufacturing Beam Aiming
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Solution Overview
Problem
Existing calibration methods for additive manufacturing devices require image acquisition to be done within the device, limiting user independence and image quality due to dependency on the device's lighting system.
Innovation Solution
A removable image capture device with visible backlighting and a transportable calibration kit that includes a calibration plate with etching layers for forming reference and test markings, allowing external image capture and improved lighting for better marking detection, enabling separate analysis and correction calculations for the firing system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If image acquisition is done within the additive manufacturing device using the device's lighting system, then the calibration process is integrated and convenient, but the image quality and lighting of test markings are insufficient
Solution Approach 1:
The calibration system is segmented into separate components: the additive manufacturing device for firing beams and the external image capture device for acquiring images. This separation allows each component to be optimized independently - the image capture device can use specialized backlighting and sensors to achieve superior image quality without being constrained by the manufacturing device's lighting system.
Solution Approach 2:
A calibration plate with etching layers serves as an intermediary between the beam firing system and the image capture device. The etching layers are selectively destroyed by the beams to create test markings, which are then imaged by the external device. This intermediary enables precise measurement while allowing the use of optimized imaging equipment separate from the manufacturing system.
2Ease of operation
If a fixed calibration tray is provided within the additive manufacturing device, then the calibration process is simplified, but the user is entirely dependent on the device for image acquisition
Solution Approach 1:
The image capture functionality is extracted from the additive manufacturing device and placed in an external, portable image capture device. The calibration plate can be removed from the manufacturing device and imaged externally. This extraction gives users complete independence - they can perform calibration, analyze images, and make corrections using equipment separate from the manufacturing device, while still maintaining ease of operation through the removable calibration plate design.
3Illumination intensity
If the lighting system of the additive manufacturing device is used for image acquisition, then the system is self-contained, but the lighting quality for marking detection is insufficient
Solution Approach 1:
The lighting is optimized locally at the calibration plate rather than using the general-purpose lighting of the manufacturing device. The external image capture device employs backlighting specifically directed at the calibration plate, providing intense, focused illumination exactly where needed for marking detection. This local optimization achieves superior lighting quality without requiring a complete overhaul of the manufacturing device's lighting system.
Solution Approach 2:
The etching layers are designed with specific optical properties that interact with the backlighting. When the backlight illuminates the calibration plate, the etching layers and underlying substrate create contrast through differences in light absorption and transmission. This optical contrast enhancement allows the imaging sensor to clearly distinguish test markings from the background, achieving excellent marking detection with dedicated backlighting.
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 independent calibration and improved image quality of test markings, providing precise aiming control corrections for the additive manufacturing device's firing system, enhancing precision and usability.
Implementation Method 1
at least one visible backlight light source located under the opening
Implementation Method 2
a sensor for acquiring at least one visible backlight light image of the calibration plate
Implementation Method 3
the at least one etching layer by incident power radiation beam being capable of being destroyed locally by the incident power radiation beam to possibly form the at least one test marking
Data Source
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AI summary
The invention relates to a removable image-capturing apparatus (200) comprising an aperture (202) intended to receive a calibration plate (10) bearing a reference marking (30) and potentially a test marking (40). According to the invention, the apparatus (200) comprises a backlighting source (204) emitting light in the visible range and located under the aperture (202), a sensor (205) for acquiring an image of the plate (10) backlit with visible light, a guiding and holding device (206) for positioning the sensor (205) above the aperture (202) with respect to the frame (201), a computer (207) configured to analyse the image, recognise the marking (30) and potentially the marking (40) in the image and compute targeting-command corrections intended for a system for firing an incident beam of radiant power from an additive manufacturing apparatus, which is separate and distinct from the apparatus (200).