IR Sensor Vapor Protection in 3D Printing
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Solution Overview
Problem
In generative 3D processes like selective laser sintering (SLS) and selective laser melting (SLM), IR sensors and other optical elements face issues due to polymer material vapors depositing on their lenses or windows, leading to measurement deviations and potential failure during long construction processes, causing material stresses and deformations in the built object.
Innovation Solution
A device is implemented with a means to generate a temperature-moderated fluid film between the electromagnetic element and the processing chamber, creating a barrier that prevents material deposits on the sensors and lasers, using a protective gas like nitrogen or argon to moderate the temperature and prevent precipitation, thereby ensuring optimal function and longevity of the sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If IR sensors are preheated to high temperatures to prevent vapor deposition, then deposition is reduced, but the sensors may become unreliable or fail due to excessive temperature over long construction times
Solution Approach 1:
A transparent protective window is introduced as an intermediary element between the IR sensor and the processing chamber. This window is exposed to the polymer vapor and can be cleaned or replaced without affecting the sensor itself. The window acts as a sacrificial barrier that protects the sensor from direct contamination while allowing infrared radiation to pass through for temperature monitoring.
Solution Approach 2:
The sensor is extracted from the harsh environment by placing it behind a protective window or in a protected position. This separates the sensitive sensor element from the harmful vapor exposure, allowing the sensor to operate at optimal temperatures without direct contact with the deposition-prone zone.
2Reliability
If IR sensors are kept at low temperatures to ensure optimal function and longevity, then sensor reliability is improved, but vapor deposition on the sensor increases
Solution Approach 1:
The protective window serves as a mediator that bears the brunt of vapor deposition. By positioning the window between the sensor and the processing chamber, the window accumulates deposits while the sensor remains clean and functional. The window can be independently maintained without compromising sensor reliability.
3Manufacturing precision
If the processing area is heated to melt polymer powder, then the generative process proceeds, but vapors are released that deposit on IR sensors and optical elements
Solution Approach 1:
The optical elements and sensors are extracted from the direct path of vapor exposure by positioning them behind protective windows or in shielded locations. This allows the processing area to be heated to required temperatures for polymer melting while the optical components remain protected from vapor contamination.
Solution Approach 2:
Protective windows act as intermediaries that separate the high-temperature processing zone from the sensitive optical components. These windows allow infrared radiation to pass through for temperature monitoring while blocking harmful vapors from reaching the sensors and other optical elements.
4Measurement precision
If lenses or windows of IR sensors are cleaned with ethanol or strong solvents to remove deposits, then measurement accuracy is restored, but the seals between the lens/window and sensor unit are damaged
Solution Approach 1:
The protective window is designed as a disposable or easily replaceable component. Instead of cleaning the expensive and sensitive sensor lens with harsh solvents that damage seals, the sacrificial window is simply replaced when contaminated. This eliminates the need for delicate cleaning operations that compromise seal integrity.
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 solution effectively prevents material deposits on IR sensors and lasers, maintaining accurate temperature control and process reliability during extended construction times, reducing the risk of sensor failure and associated quality impairments in the manufactured objects.
Implementation Method 1
a temperature-moderated fluid film is generated between the electromagnetic element and the processing chamber volume
Implementation Method 2
creating a barrier that prevents material deposits on the sensors and lasers, using a protective gas like nitrogen or argon to moderate the temperature
Implementation Method 3
using a protective gas like nitrogen or argon to moderate the temperature and prevent precipitation
Implementation Method 4
at least one electromagnetic element is used to inject electromagnetic radiation into the processing chamber
Implementation Method 5
Supplying energy to selected areas of the layer that correspond to a cross section of the object to be formed in the layer, so as to melt the powder at the selected areas
Implementation Method 6
the temperature of the target surface and potential other surfaces inside the processing chamber is determined by acquiring the radiation emitted by them
Implementation Method 7
The surface temperature of the target surface is monitored using infrared sensors, for example
Data Source
AI summary
Method and device for producing a 3D object by means of a generative 3D-method, for example, selective laser sintering (SLS) and selective laser melting (SLM). An infrared sensor can be cross-flown by a tempered fluid in order to prevent the infrared sensor, which is provided in the process chamber of the device, from being impaired by monomer deposits, oligomers or solid material particles during the construction thereof.