Simulated Irradiation Calibration for Multi-Beam 3D Printing
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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 positioning deviations between multiple energy beams, leading to inefficiencies in the overall manufacturing time.
Innovation Solution
A method involving the generation of multiple calibration patterns at different positions by each energy beam, determining position information, calculating a calibration quality value based on deviations, simulating pattern changes with adjusted irradiation parameters, and repeating the process until optimal calibration is achieved, using a weight function to prioritize critical areas of the build plane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple calibration steps are performed to avoid stitching errors and positioning deviations, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The patent combines multiple calibration steps into a single integrated calibration process. The determination device simultaneously determines position information for multiple calibration patterns from different irradiation units in one operation, rather than requiring separate calibration steps for each beam. This merging of calibration operations reduces calibration time while maintaining positioning precision through comprehensive position information analysis.
Solution Approach 2:
The patent implements feedback by calculating a calibration quality value based on determined position information and using this feedback to assess calibration status. The system evaluates the accuracy of calibration patterns and provides feedback on calibration quality, enabling precise calibration assessment without requiring multiple iterative calibration steps, thus reducing time loss while maintaining precision.
2Reliability
If comprehensive calibration of multiple energy beams is performed, then reliability is improved, but device complexity increases
Solution Approach 1:
The determination device serves multiple functions: it determines position information for calibration patterns from multiple irradiation units, calculates calibration quality values, and assesses overall calibration status. This multi-functional device consolidates what would otherwise require multiple specialized calibration systems, reducing device complexity while maintaining comprehensive calibration accuracy for all energy beams.
Solution Approach 2:
The patent introduces a determination device as an intermediary that mediates the calibration process between multiple irradiation units and the control system. This intermediary device centralizes the calibration assessment function, simplifying the overall system architecture while ensuring reliable calibration of all energy beams through unified position information determination and quality assessment.
Data Source
AI summary
An adjustment to an irradiation parameter corresponding to a first irradiation unit and/or a second irradiation unit of an irradiation device of an additive manufacturing apparatus may be performed based at least in part on a simulation. The simulation may include simulating generation of a plurality of first calibration patterns by the first irradiation unit and a plurality of second calibration patterns by the second irradiation unit with a simulated change to the irradiation parameter of the irradiation device, and determining a calibration quality value based at least in part on position information relating to the plurality of first calibration patterns and the plurality of second calibration patterns. The calibration quality value may include an indication as to whether a calibration quality of the apparatus would be improved as a result of the adjustment to the irradiation parameter.