Laser Additive Calibration via Vision Feedback
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Solution Overview
Problem
Current laser additive manufacturing processes face inaccuracies in melt patterns due to operator variability in calibrating laser and scanner delays, leading to non-uniform surfaces and increased man-hours for calibration, especially as more operators are involved.
Innovation Solution
A method for calibrating laser and scanner delay settings by comparing on and off positions on a test plate to standard positions, adjusting differences to match known quality builds, which can be automated using software and monitoring devices to standardize scan motions and reduce variability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual calibration of laser and scanner delays is performed by operators, then calibration can be completed, but operator variation leads to inconsistent manufacturing precision and increased calibration time
Solution Approach 1:
The patent replaces manual operator calibration with an automated vision-based system using cameras to capture and analyze test patterns. This substitution eliminates human variability in calibration while maintaining or improving precision, directly resolving the contradiction between manufacturing precision and calibration time.
Solution Approach 2:
The system creates a digital copy of the physical test pattern through camera imaging and uses image processing to extract calibration data. This copying approach enables automated, repeatable measurements without manual intervention, reducing calibration time while improving consistency.
2Productivity
If more operators are involved in calibration, then more builds can be calibrated, but operator variation increases and standardization decreases
Solution Approach 1:
By replacing multiple human operators with a single automated vision system, the patent eliminates inter-operator variation while maintaining high productivity. The automated system can calibrate multiple builds consistently without the degradation in precision that occurs when different operators perform calibration.
Solution Approach 2:
The system transforms the calibration process from a manual parameter-adjustment task to an automated image-analysis task. By changing the fundamental parameter measurement approach from human judgment to computer vision, the system achieves both high productivity and consistent precision across all builds.
3Productivity
If laser on and off delays are not accurately calibrated, then the process is simpler and faster, but melt patterns become inaccurate and surface finish deteriorates
Solution Approach 1:
The system performs preliminary calibration using a test pattern and camera-based measurement before actual production builds. This preliminary action establishes accurate laser on/off timing parameters, ensuring both fast calibration and high melt pattern accuracy in subsequent production.
Solution Approach 2:
The vision system captures images of the test pattern, compares actual laser on/off positions to target positions, and provides feedback for adjusting delay parameters. This closed-loop feedback ensures accurate calibration while maintaining efficient process speed.
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 reduces operator-to-operator variation, shortens calibration time, and ensures consistent product quality by standardizing laser and scanner head delay settings, resulting in improved geometric tolerance and surface finish.
Implementation Method 1
a laser beam to sinter or melt a powder material
Implementation Method 2
The physical processes associated with laser sintering or laser melting include heat transfer to a powder material
Implementation Method 3
The energy beam 136 sinters or melts a cross sectional layer of the object being built under control of the galvo scanner 132
Data Source
AI summary
This invention relates to a method for calibrating the delay settings of a laser or scanner head in a laser additive manufacturing process. More particularly, the invention relates to calibrating delay settings during run-ins and run-outs of a laser scanning process.