In Situ 3D Manufacturing Sensing for Closed-Loop Layer Control
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Solution Overview
Problem
Current additive manufacturing systems lack real-time, in-situ sensing and characterization capabilities for roughness, geometrical shapes, composition, defects, and temperature, leading to challenges in controlling microstructure and residual stresses, especially in high-temperature applications like small modular reactors, which require precise control and stability.
Innovation Solution
A method and apparatus utilizing lasers, autofocusing scanners, powder injection systems, dichroic filters, imagers, processors, and non-destructive probing inspection systems to monitor and control three-dimensional manufacturing parameters in real-time, allowing for feedback and feedforward control to adjust manufacturing parameters based on continuous data analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If real-time sensing and characterization capabilities are added to additive manufacturing systems, then manufacturing precision and reliability are improved, but device complexity increases
Solution Approach 1:
The patent combines multiple sensing capabilities (imaging, spectroscopy, interferometry) and manufacturing functions into a single integrated additive manufacturing system. The sensor head includes cameras, spectrometers, and interferometers that work together with the laser processing system to provide comprehensive real-time monitoring and control of microstructure, temperature, and residual stresses during manufacturing.
Solution Approach 2:
The system employs multi-functional sensors that can simultaneously perform multiple measurement tasks. For example, the imaging system captures both visual information and thermal data, while the spectrometer analyzes both composition and temperature. This multi-functionality reduces the need for separate dedicated sensors for each measurement type.
2Measurement precision
If multiple sensing systems are integrated for comprehensive monitoring, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple sensing modalities into a single sensor head that can be positioned close to the manufacturing zone. The sensor head integrates cameras for imaging, spectrometers for compositional analysis, and interferometers for surface roughness measurement, allowing simultaneous multi-parameter characterization without requiring separate sensor systems.
Solution Approach 2:
The sensing systems are nested within a compact sensor head structure that houses multiple measurement instruments. The camera, spectrometer, and interferometer are arranged in a nested configuration where smaller components are positioned within or alongside larger ones, maximizing space utilization and reducing overall system complexity.
3Manufacturing precision
If real-time feedback control is implemented, then manufacturing precision is improved, but loss of time in processing increases
Solution Approach 1:
The sensing and measurement systems operate continuously throughout the additive manufacturing process without interrupting the laser processing. The sensor head maintains constant monitoring of the melt pool, deposited material, and process parameters, enabling real-time feedback control that adjusts manufacturing parameters on-the-fly without stopping production or adding significant processing time.
Solution Approach 2:
The system implements closed-loop feedback control where sensor data is continuously analyzed and used to adjust manufacturing parameters in real-time. The feedback mechanism processes measurement data and automatically modifies laser power, scanning speed, or other process parameters to maintain optimal manufacturing conditions and ensure part quality.
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 precise control over microstructure and surface quality, reducing residual stresses and defects, and improving the accuracy and efficiency of additive manufacturing by providing real-time monitoring and adjustment of manufacturing parameters, resulting in higher-quality metal and ceramic parts.
Implementation Method 1
one or more lasers configured to generate electromagnetic radiation
Implementation Method 2
a dichroic filter positioned between the autofocusing scanner and the stage
Data Source
AI summary
Methods and apparatuses for manufacturing are disclosed, including (a) providing an apparatus having: a laser; scanner; powder injection system; powder spreading system; dichroic filter; imager-and-processor; and computer; (b) programming the computer with specifications of a sample; (c) using the computer to set initial parameters based on the sample specifications; (d) adjusting a stage to position the sample; (e) focusing and scanning electromagnetic radiation onto the sample while powder is concurrently injected onto the sample in order to deposit a layer; (f) capturing two-dimensional images of the sample and probing the sample to determine whether the deposited layer was manufactured per the specifications; (g) use the computer to adjust the three-dimensional manufacturing parameters based on the determination made in step (f) prior to additively manufacturing a subsequent layer or making repairs; and (h) repeating steps (d), (e), (f), and (g) until the manufacture is complete. Other embodiments are described and claimed.