Fiducial Marker Tomosynthesis for Composite Flaw Detection
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Solution Overview
Problem
Current non-destructive evaluation techniques for composite materials, such as 3D x-ray imaging and ultrasound, are inefficient, costly, and fail to detect complex structural flaws like closed delamination and ply wrinkling, especially in large structures, and 3D printing layered structures face similar challenges with low x-ray contrast and hidden flaws.
Innovation Solution
Incorporating fiducial markers that attenuate x-rays more than the composite material during manufacturing, followed by x-ray 3D tomosynthesis imaging to determine the relative locations of these markers, enabling the reconstruction of a combined three-dimensional density function to identify structural integrity and detect counterfeit products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If 3D x-ray imaging is used to detect structural flaws in composite materials, then detection capability is improved, but cost and complexity increase significantly
Solution Approach 1:
The patent segments the imaging process into multiple 2D x-ray projections taken at different angles, which are then computationally reconstructed into a 3D tomosynthesis image. This approach uses standard 2D imaging equipment rather than requiring complex 3D x-ray scanners, thereby reducing system complexity while maintaining detection capability for internal flaws like delamination and ply wrinkling in composite materials.
Solution Approach 2:
The patent creates multiple copies of the object from different angular positions through sequential 2D x-ray imaging, then uses computational algorithms to synthesize a 3D representation. This copying approach allows the use of simple 2D detectors and emitters to achieve 3D visualization, avoiding the need for complex 3D imaging hardware while improving detection of structural integrity issues.
2Ease of manufacture
If conventional 3D printing layer-by-layer manufacturing is used, then manufacturing flexibility is improved, but hidden voids and flaws remain undetected
Solution Approach 1:
The patent incorporates fiducial markers during the 3D printing manufacturing process itself, embedding them within the layered structure as it is being formed. These markers serve as reference points that can be detected in subsequent x-ray imaging to identify ply wrinkling, voids, and other manufacturing defects. This preliminary incorporation of detection references allows real-time or post-manufacturing inspection without requiring separate complex scanning processes.
Solution Approach 2:
The patent uses fiducial markers with distinct x-ray attenuation properties (analogous to color changes in visual detection) that contrast with the composite material. These markers appear as distinctive features in the 2D x-ray projections and can be identified through image processing algorithms, enabling detection of manufacturing defects such as voids and wrinkling that would otherwise be hidden within the layered structure.
3Measurement precision
If fiducial markers are incorporated during manufacturing, then detection precision is improved, but manufacturing process complexity increases
Solution Approach 1:
The patent introduces fiducial markers as intermediary elements during manufacturing that facilitate subsequent detection. These markers are simple, well-defined objects with known x-ray attenuation characteristics that serve as references for identifying defects. By incorporating these simple intermediary markers during the printing process, the system achieves high detection precision for complex flaws without requiring complex detection equipment, as the markers provide stable reference points for image processing algorithms.
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 efficient, real-time detection of structural integrity and counterfeit materials by forming a 3D tomosynthesis image of entire structures, overcoming limitations of existing methods in detecting complex flaws and ply wrinkling.
Implementation Method 1
distributing fiducial markers (which attenuate x-rays to an extent greater than the rest of the material) within the composite material
Implementation Method 2
emitting x-ray radiation from an emitter and detecting it at a detector
Data Source
AI summary
A method to identify and/or assess structural integrity of a composite material, by distributing fiducial markers within the composite material during manufacture, and subsequently creating x-ray 3D tomosynthesis images of the composite material using an array of x-ray emitters and a digital x-ray detector, the 3D tomosynthesis images being used to determine the relative location of at least some of the fiducial markers. This enables detection of counterfeit products by comparison with recorded data at manufacture and detection of an internal degradation of the material indicated by movement of the fiducial markers. Relative locations of fiducial markers in a first set of images are compared with relative locations of fiducial markers in a second set of images, to identify common fiducial markers and thereby determine an offset therebetween. Both sets of images may be used to reconstruct a combined three-dimensional density function.