High Resolution Imaging Bar for Additive Manufacturing Layer Monitoring
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Solution Overview
Problem
Existing additive manufacturing systems face issues with layer and component quality due to excess heat, heat variation, uneven powder layers, and limited imaging resolution, leading to reduced dimensional accuracy and feature precision, especially around edges and in larger components.
Innovation Solution
A high-resolution imaging bar with a detector array and imaging element positioned between the array and the material, extending along a direction and moving to generate detailed images of build layers, capable of capturing features at a scale of a tenth of a millimeter or better, addressing misalignment, unevenness, and melt variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a static camera with low exposure is used to track the focused laser, then the imaging device can capture light during the melting process, but the resolution is limited and only portions of the melt pool and solidified layer can be imaged without reference to specific positions
Solution Approach 1:
The imaging system is divided into multiple linear detector arrays arranged in a specific pattern, where each array captures a portion of the build layer. This segmentation allows the system to achieve high resolution imaging across the entire build area by combining data from multiple arrays, rather than requiring a single complex high-resolution camera.
Solution Approach 2:
The patent transitions from using a single static camera capturing two-dimensional images to using multiple linear detector arrays arranged in a multi-dimensional configuration. The arrays are positioned at different locations and orientations to capture the build layer from multiple perspectives, enabling comprehensive high-resolution imaging of the entire melt pool and solidified layer.
2Measurement precision
If a static camera is used to image the solidified layer, then the device structure is simple, but the imaging resolution is limited and cannot detect small feature changes on larger components
Solution Approach 1:
The imaging system provides real-time feedback during the additive manufacturing process by continuously monitoring the build layer quality. The detector arrays capture images of each solidified layer, and the system can detect defects, dimensional inaccuracies, and feature variations immediately after layer formation, enabling real-time quality control without slowing down the manufacturing process.
Solution Approach 2:
The imaging system performs preliminary inspection of each build layer immediately after it is solidified but before the next layer is deposited. This allows for early detection of potential quality issues, enabling corrective actions to be taken before they propagate to subsequent layers, thereby maintaining high manufacturing efficiency while ensuring quality.
3Manufacturing precision
If the melt pool size varies due to thermal conductivity variations, then the accuracy of printed structures varies, but increasing laser power to compensate reduces heat variation and melting inconsistencies
Solution Approach 1:
The patent replaces mechanical/thermal compensation methods with an optical imaging-based monitoring and control system. Instead of adjusting laser power mechanically to compensate for thermal conductivity variations, the system uses detector arrays to optically measure actual melt pool dimensions and solidified layer geometry, then feeds this information back to adjust processing parameters for precise dimensional control.
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 early detection of potential problems during the manufacturing process, resulting in higher quality components, saving time and material by allowing for corrections and discarding unsalvageable parts early on.
Implementation Method 1
an imaging element positioned between the at least one detector array and the material... configured to generate an image of a build layer within the material
Data Source
AI summary
An imaging device for an additive manufacturing system is provided. The additive manufacturing system includes a material. The imaging device includes a high resolution imaging bar including at least one detector array, and an imaging element positioned between the at least one detector array and the material. The high resolution imaging bar is displaced from the material along a first direction and extends along a second direction. The high resolution imaging bar is configured to generate an image of a build layer within the material.