In-situ Height and Thermal Inspection for Additive Manufacturing Defects
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Solution Overview
Problem
Additive manufacturing faces challenges in detecting and mitigating defects such as lack-of-fusion and Keyhole/material-induced gas porosity, which hinder the speed of adoption and component quality.
Innovation Solution
A system and method for inspecting height and thermal information using phase mapping and height mapping sensors, combined with thermal analysis, emission profile, temperature, and emissivity data, to identify problem areas and predict defects, enabling real-time defect detection and correction through in situ monitoring and closed-loop feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inspection methods are used, then device complexity is reduced, but measurement precision and defect detection capability deteriorate
Solution Approach 1:
The patent combines multiple sensing modalities (phase mapping, height mapping, thermal analysis, emission profile, temperature, and emissivity sensors) into an integrated inspection system. This merging of previously separate inspection methods enables comprehensive defect detection with high precision while managing system complexity through unified data processing architecture.
Solution Approach 2:
The inspection system is designed to perform multiple functions simultaneously: phase mapping for surface inspection, height mapping for topography, thermal analysis for heat distribution, emission profile for material characteristics, temperature monitoring, and emissivity measurement. This multi-functionality allows a single system to detect various defect types (lack-of-fusion, Keyhole porosity, gas porosity) that would require separate specialized systems.
2Productivity
If real-time inspection is implemented, then productivity is improved through rapid defect detection, but device complexity increases due to multiple sensors and processing requirements
Solution Approach 1:
The system implements continuous real-time inspection during the additive manufacturing process rather than post-processing inspection. Multiple sensors operate simultaneously and continuously monitor the build process, enabling immediate defect detection and mitigation while maintaining manufacturing throughput. The integrated data processing architecture handles the continuous data stream from all sensors without bottlenecking the manufacturing process.
3Reliability
If comprehensive defect detection is achieved through multiple sensing modalities, then reliability is improved, but difficulty of detecting and measuring specific defects worsens due to data integration complexity
Solution Approach 1:
The patent segments the inspection process into distinct sensing modalities (phase mapping, height mapping, thermal analysis, emission profile, temperature, emissivity), each optimized for detecting specific defect types. The data processing system then integrates these segmented data streams, allowing comprehensive defect detection while managing complexity through modular data handling and analysis.
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 real-time detection and mitigation of defects, improving additive manufacturing quality by integrating in situ height inspection, coaxial thermometry, and optical tomography for predictive analytics and beam shaping to heal material deposits.
Implementation Method 1
use one of a phase mapping sensor and a height mapping sensor to identify a plurality of problem areas
Implementation Method 2
use one of a phase mapping sensor and a height mapping sensor to identify a plurality of problem areas
Implementation Method 3
investigate the plurality of problem areas with at least one of thermal analysis, emission profile, temperature, and emissivity data
Data Source
Figure 1A~1D
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AI summary
A system for inspecting height and thermal information in additive manufacturing includes at least one processor to determine material quality and formation of porosity during additive manufacturing and use one of a phase mapping sensor and a height mapping sensor to identify a plurality of problem areas and investigate the plurality of problem areas with at least one of thermal analysis, emission profile, temperature, and emissivity data.