Additive Manufacturing Head Calibration for Beam Focus and Position
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing devices with three-axis head systems face challenges in achieving optimal calibration for precise beam focusing and positioning due to geometric deformations across the powder bed, leading to non-linear 'pillow-shaped' deformations and suboptimal correction in X and Y axes, which affects the energy transmission and object quality.
Innovation Solution
An automatic calibration kit and method using a calibration plate with visible reference marks and a radiation-sensitive firing support, combined with optical measurement equipment, to determine and apply precise corrections to the head system controls, ensuring better calibration in X and Y axes and optimized focusing in Z axis, by capturing images and processing patterns to identify necessary corrections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a three-axis head system with galvanometers and DFM is used to improve beam positioning precision, then positioning precision is improved, but geometric deformations (pillow-shaped distortion and focus variation) occur across the working plane
Solution Approach 1:
The patent applies preliminary action by pre-calibrating the head system using a calibration plate with reference marks before actual manufacturing. The calibration process determines correction values for each position on the working plane, accounting for pillow-shaped distortion and focus variation. These correction values are stored and applied during subsequent manufacturing operations, allowing the system to compensate for geometric deformations in advance and maintain both positioning precision and focus uniformity across the entire working plane.
2Measurement precision
If correction tables are used to correct non-linear deformations in X and Y axes, then positioning accuracy is improved, but focus control in Z axis remains suboptimal
Solution Approach 1:
The patent applies universality by integrating both X-Y positioning correction and Z-axis focus control into a single comprehensive calibration system. The calibration plate includes reference marks that enable determination of both lateral positioning errors and focal plane variations. The correction table generated from calibration data simultaneously compensates for pillow-shaped distortion in X-Y directions and focus variation in the Z direction, making the calibration system multi-functional and eliminating the need for separate correction processes.
3Measurement precision
If conventional calibration methods with calibration plates are used, then positioning corrections can be determined, but the process is time-consuming and requires manual intervention
Solution Approach 1:
The patent applies self-service by implementing an automated calibration process where the system performs self-calibration using the calibration plate without requiring manual intervention. The automated process includes: automatically positioning the beam at reference marks, detecting the actual positions, calculating correction values, and storing them in the correction table. This self-calibrating capability significantly reduces calibration time while maintaining high accuracy, and allows the system to be quickly re-calibrated if needed.
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 improved precision in beam positioning and focusing, achieving better calibration and energy control, resulting in enhanced quality and consistency of three-dimensional objects produced by additive manufacturing.
Implementation Method 1
An automatic calibration kit and method using a calibration plate with visible reference marks and a radiation-sensitive firing support, combined with optical measurement equipment, to determine and apply precise corrections to the head system controls
Implementation Method 2
a firing support made from at least one material sensitive to the radiation of the source
Data Source
AI summary
A kit for the calibration of a head system of a power radiation source of an additive manufacturing device comprises: a calibration plate having a plurality of reference marks, and a firing support made from at least one material sensitive to the radiation of the source, this support leaving the reference marks of the calibration plate visible when it is in place thereon, characterized in that the firing support comprises a plurality of windows distributed in such a way as to become superposed with the various reference marks of the calibration plate and leave them visible when the firing support is in place on the calibration plate. There is also a method for calibrating such a system.