Irradiation Beam Calibration for Precise 3D Printing Alignment
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Solution Overview
Problem
The calibration process for irradiation devices in additive manufacturing is cumbersome and time-consuming, requiring multiple calibration steps to avoid stitching errors and ensure precise alignment of energy beams, which can lead to inefficiencies in the manufacturing process.
Innovation Solution
A method involving the generation of multiple calibration patterns at different positions using two energy beams, determining position information, and simulating adjustments to irradiation parameters to optimize calibration quality, reducing the number of calibration steps and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple calibration steps are performed to ensure precise alignment of energy beams, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The patent applies preliminary action by performing a simulation of the calibration process before actual calibration. The simulation predicts optimal irradiation parameters and expected calibration quality, allowing the system to prepare correction values in advance. This preliminary computational step reduces the need for multiple iterative calibration attempts, thereby decreasing calibration time while maintaining precision.
Solution Approach 2:
The patent implements feedback through an iterative calibration process where actual calibration quality is measured and compared against simulated predictions. Based on this feedback, correction values are adjusted and reapplied. The system continuously refines the calibration by using measurement results to inform subsequent calibration steps, achieving high precision with fewer iterations than traditional methods.
2Manufacturing precision
If simulation and optimization of irradiation parameters are performed, then calibration quality is improved, but use of energy and computational resources increases
Solution Approach 1:
The patent applies partial action by performing simulation and optimization only for critical parameters and regions that have the greatest impact on calibration quality. Rather than exhaustively analyzing all possible parameters, the system identifies and focuses computational resources on the most influential factors, achieving high calibration quality with reduced computational energy consumption.
3Manufacturing precision
If correction values are applied to irradiation parameters, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The patent introduces an intermediary computational module that acts as a mediator between the irradiation device and the calibration process. This intermediary software component handles the complex calculations, simulation, and generation of correction values, while the physical irradiation device itself remains relatively simple. The computational intermediary absorbs the complexity, allowing the hardware to maintain simplicity while achieving high precision.
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 approach allows for a more efficient calibration process by determining the optimal irradiation parameters, minimizing deviations, and improving the overall calibration quality of the irradiation device, thereby reducing manufacturing time and enhancing the precision of additive manufacturing.
Implementation Method 1
generating at least two first and two second calibration patterns, wherein the at least two first calibration patterns are generated in at least two different first positions via the first energy beam and the at least two second calibration patterns are generated in at least two different second positions via the second energy beam
Data Source
AI summary
A method of calibrating an irradiation device for an apparatus for additively manufacturing three-dimensional objects includes generating at least two first calibration patterns in at least two different first positions by a first energy beam and at least two second calibration patterns in at least two different second positions by a second energy beam on a build plane. Position information is determined relating to the at least two first calibration patterns and the at least two second calibration patterns. A weight factor is assigned to at least one of: the at least two first calibration patterns and the at least two second calibration patterns. A calibration quality value is determined based at least in part on the position information and the weight factor where the calibration quality value relates to a calibration status of the irradiation device.