In-Situ Model Comparison for Additive Layer Thickness Control

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Solution Overview

Problem

Additive manufacturing systems face challenges in maintaining accurate layer thickness due to varying capture efficiency of the melt pool, leading to components with dimensions that deviate from specifications, resulting in rework or waste.

Innovation Solution

Incorporation of a topology monitoring system that captures data on the as-deposited layer's position, compared to a modeled position, allowing a computing device to adjust deposition parameters of the powder and energy delivery devices to align with the model, using machine learning for adaptive control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If additive manufacturing processes are used to fabricate components, then rapid prototyping and complex three-dimensional structures can be formed, but the actual dimensions of as-deposited layers may depart from desired dimensions due to varying capture efficiency

Engineering Contradiction:

Improverapid prototypingVSAvoidlayer thickness accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent implements a feedback mechanism where the actual position of the as-deposited layer surface is measured and compared to the modeled position, and deposition parameters are adjusted based on the difference. This closed-loop control ensures that manufacturing precision is maintained while preserving the productivity benefits of additive manufacturing.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces mechanical measurement and manual inspection methods with an optical measurement system that non-contactly measures the as-deposited layer surface position. This substitution enables real-time monitoring and adjustment without interrupting the manufacturing process, maintaining both precision and productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If deposition parameters are adjusted to improve layer thickness accuracy, then manufacturing precision improves, but the complexity of the control system increases

Engineering Contradiction:

Improvedimensional accuracyVSAvoidcontrol system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent creates a digital copy or model of the expected as-deposited layer surface position based on deposition parameters and material properties. This virtual model is then compared with actual measurements, allowing for straightforward parameter adjustment without complex control algorithms, thus improving precision while limiting the increase in system complexity.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent adjusts deposition parameters such as energy delivery, powder flow rate, and scan speed in a systematic manner based on the measured differences between actual and modeled layer positions. These parameter changes are made in response to quantitative feedback, providing a structured approach to improving precision without overwhelming complexity.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If real-time monitoring and adjustment of deposition parameters is implemented, then build quality improves and waste is reduced, but the cost and complexity of the system increases

Engineering Contradiction:

Improvebuild qualityVSAvoidmonitoring system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent employs a feedback mechanism where the actual position of the as-deposited layer is measured and compared to the modeled position, and deposition parameters are adjusted based on the difference. This closed-loop control ensures that manufacturing precision is maintained while preserving the productivity benefits of additive manufacturing.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Improves the build quality of components by reducing deviations from desired dimensions, minimizing waste and rework through real-time adjustment of deposition parameters.

Implementation Method 1

an energy delivery device that delivers energy to a build surface of a component to form a melt pool

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

a powder delivery device that directs a powder stream toward the melt pool to form an as-deposited layer on the build surface

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Data Source

PatentUS20250276376A1In-situ model comparison for additive manufacturing systems

Publication Date: 2025.09.04 ROLLS ROYCE CORP

AI summary

An additive manufacturing system includes an energy delivery device and a powder delivery device configured to form an as-deposited layer on a build surface of the component. The system includes a topology monitoring system configured to capture data indicative of a position of a surface of the as-deposited layer, and also includes a computing device. The computing device is configured to receive the data and determine an actual position of the surface of the as-deposited. The computing device is configured to compare the actual position to a modeled position of the surface of the as-deposited layer. The computing device is further configured to determine a difference between the actual position and the modeled position of the as-deposited layer and control at least one of the energy delivery device or the powder delivery device based on the difference between the actual position and the modeled position of the as-deposited layer.