Interlace Calibration for Additive Manufacturing Scan Alignment
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Solution Overview
Problem
Current additive manufacturing (AM) apparatuses face challenges in achieving consistent and dimensionally accurate components due to the need for precise calibration of various components, including galvanometers and build units, which is critical for accurate layer-by-layer buildup.
Innovation Solution
The method involves forming solidified portions in distinct scan regions while the build unit is in different locations, allowing for the update of the additive manufacturing apparatus's alignment based on the detected alignment of these solidified portions. This approach enables interlace calibration, ensuring accurate alignment between adjacent scan zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual calibration methods are used for galvanometers and build units, then the calibration process can be performed, but the dimensional accuracy and consistency of components deteriorate due to alignment errors between adjacent scan zones
Solution Approach 1:
The system performs self-calibration by automatically detecting alignment errors between scan zones using the solidified portions as reference features and adjusting calibration parameters without requiring manual intervention or external measurement tools
Solution Approach 2:
The system uses detected alignment errors from solidified portions as feedback to automatically adjust and update calibration parameters for the galvanometer and build unit positioning, creating a closed-loop calibration process that improves measurement precision
2Productivity
If traditional calibration approaches are used, then the calibration process can be completed, but the calibration time and productivity are reduced due to manual measurement and adjustment procedures
Solution Approach 1:
The system incorporates calibration features (solidified portions) directly into the initial build layers during normal manufacturing operations, so that calibration data is collected as part of the production process rather than requiring separate dedicated calibration time
Solution Approach 2:
The system automatically performs calibration measurements and parameter updates using its own manufacturing operations, eliminating the need for separate manual calibration procedures and external measurement equipment, thereby significantly reducing calibration time
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 method enhances the calibration process, leading to improved dimensional accuracy and consistency of components produced by additive manufacturing, by ensuring precise alignment and positioning of the build unit and scanning systems.
Implementation Method 1
a laser beam to sinter or melt a fine powder
Implementation Method 2
The physical processes associated with laser sintering or laser melting include heat transfer to a powder material
Implementation Method 3
an electron beam or electromagnetic radiation such as a laser beam, to sinter or melt a powder material
Data Source
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AI summary
A method, apparatus, and program for calibrating an additive manufacturing apparatus. In one aspect, a method is disclosed for calibrating an additive manufacturing apparatus. The method includes forming a first solidified portion within a first scan region, wherein the solidified portion within the first scan region is formed by irradiating a build material while a build unit is in a first location. The method further includes forming a second solidified portion within a second scan region, wherein the second solidified portion within the second scan region is formed by irradiating a build material while a build unit is in a second location different from said first location. An alignment of the additive manufacturing apparatus determined based on the detected alignment of the first solidified portion and the second solidified portion.