Optical Fiber Beam Calibration for Additive Manufacturing Alignment
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Solution Overview
Problem
Existing additive manufacturing machines face challenges in accurately calibrating their energy beam systems, which affects the alignment and material properties of additively manufactured three-dimensional objects, leading to inconsistencies in the manufacturing process.
Innovation Solution
The implementation of a calibration system that uses a calibration beam emitted through an optical fiber, reflected off a substrate, and detected by a fiber end, allowing for alignment adjustments based on signal intensity and position, ensuring precise alignment with the optical axis to improve beam alignment and object quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional calibration methods are used for energy beam systems, then the manufacturing process can proceed, but the alignment precision and material properties of additively manufactured objects deteriorate due to misalignment
Solution Approach 1:
The patent replaces traditional mechanical alignment methods with an optical detection system. A detection device measures the position of a calibration beam reflected from a calibration substrate, providing precise alignment data without mechanical contact. This substitution enables accurate beam alignment and consistent material properties through optical feedback rather than mechanical adjustment.
Solution Approach 2:
The calibration system implements feedback by detecting the position of the calibration beam and using this information to determine and correct alignment deviations. The detection device provides real-time alignment data, allowing the system to adjust the energy beam system to achieve optimal alignment, thereby improving both alignment precision and manufacturing consistency.
2Manufacturing precision
If no calibration system is implemented, then the device complexity remains low, but the alignment precision and object quality deteriorate
Solution Approach 1:
The patent introduces a calibration substrate as an intermediary element between the energy beam system and the detection device. This substrate reflects the calibration beam to the detector, enabling alignment measurement without requiring complex direct measurement systems. The intermediary simplifies the overall calibration system while achieving precise alignment capability.
Solution Approach 2:
The system uses a calibration beam as a copy or representation of the actual energy beam used in manufacturing. By measuring the alignment of this calibration copy, the system can determine and correct alignment of the main beam without interfering with the manufacturing process, thereby achieving precise alignment with minimal added complexity.
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
This method enhances the alignment of the energy beam system, resulting in improved material properties and consistency of additively manufactured objects by compensating for misalignments and optimizing beam orientation.
Implementation Method 1
a calibration system that uses a calibration beam emitted through an optical fiber, reflected off a substrate, and detected by a fiber end
Implementation Method 2
the reflected beam including a portion of the calibration beam having been reflected by the reflective surface
Data Source
AI summary
Methods of calibrating an additive manufacturing machine include detecting a reflected beam becoming incident upon a detection device, the reflected beam comprising a portion of a calibration beam having been reflected by a reflective surface of a calibration substrate; and determining an alignment of the reflected beam and/or the calibration beam with an optical axis based at least in part on detecting the reflected beam becoming incident upon the detection device; wherein, the reflected beam becomes incident upon a fiber end of an optical fiber and propagates through the optical fiber prior to becoming incident upon the detection device, the optical fiber defining a portion of a detection path from the reflective surface to the detection device.