Fiducial Mark Alignment for Additive Manufacturing Build Plates

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Solution Overview

Problem

In additive manufacturing systems, particularly Direct Metal Laser Melting (DMLM) systems, the misalignment of build plates during the transfer of unfinished components between multiple systems increases build time, as existing methods lack effective alignment mechanisms.

Innovation Solution

An alignment system is introduced, featuring a build plate with projected or permanently coupled fiducial marks and an optical detector to detect the marks' position relative to the laser device, allowing for precise alignment across multiple DMLM systems by adjusting the build plate and scanning device positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple DMLM systems are used to build complex components, then productivity is improved, but misalignment of the build plate occurs when transferring unfinished components between systems

Engineering Contradiction:

Improvebuild timeVSAvoidbuild plate alignment

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent introduces fiducial marks as an intermediary reference system that mediates between multiple DMLM systems. These marks serve as a common language for alignment, allowing the build plate to be accurately positioned in different systems without direct system-to-system calibration. The fiducial marks act as a mediator that translates positioning information across different DMLM systems, resolving the alignment problem while maintaining the productivity benefits of using multiple systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent implements an optical detection system that provides feedback on the build plate position by detecting fiducial marks. This feedback mechanism allows the system to measure actual alignment deviations and compensate for them through software correction. The feedback loop enables continuous monitoring and adjustment of build plate positioning, ensuring manufacturing precision is maintained when transferring components between multiple DMLM systems.

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If build plate alignment is manually adjusted between DMLM systems, then manufacturing precision can be maintained, but build time increases due to transfer and realignment processes

Engineering Contradiction:

Improvecomponent alignmentVSAvoidbuild time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-defining fiducial mark positions on the build plate before component transfer. These marks are established in advance as known reference points, eliminating the need for time-consuming manual alignment measurements during the transfer process. The preliminary positioning of reference markers enables rapid automated alignment, significantly reducing the time loss associated with transferring build plates between DMLM systems while maintaining manufacturing precision.

Inventive Principle:

Principle #10Preliminary action

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 solution enables the seamless transfer and alignment of build plates across multiple DMLM systems, reducing build time and ensuring accurate component fabrication by maintaining precise positioning.

Implementation Method 1

an optical detector configured to detect the location of each of the fiducial marks on the build plate

Methodology Applied

Scientific EffectOptical detection: Reflection

Implementation Method 2

The laser device generates a laser beam that melts the powder material on the build plate

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 3

The laser beam generates a melt pool on the build plate

Methodology Applied

Scientific EffectLight absorption: Absorption (EM radiation)

Data Source

PatentUS10814427B2Systems and methods for additive manufacturing in-build assessment and correction of laser pointing accuracy

Publication Date: 2020.10.27 GENERAL ELECTRIC CO

AI summary

An additive manufacturing system includes a laser device, a build plate, a first scanning device, and an alignment system. The laser device is configured to generate a laser beam. The build plate has a position relative to the laser device. The first scanning device is configured to selectively direct the laser beam across the build plate. The laser beam generates a melt pool on the build plate. The alignment system includes a fiducial marks projector configured to project a plurality of fiducial marks across the build plate. Each fiducial mark has a location on the build plate. The alignment system also includes an optical detector configured to detect the location of each of the fiducial marks on the build plate. The alignment system is configured to detect the position of the build plate relative to the laser device.