Laser Alignment on Carrier Plates for Prefabricated 3D Printing
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Solution Overview
Problem
Conventional 3D printing systems lack precise absolute alignment of energy beams, which is necessary for certain fabrication processes, especially when working with prefabricated bodies.
Innovation Solution
A three-dimensional printing system that includes a carrier plate with receptacles and alignment targets, where the laser system operates at two power levels, using low power for alignment and high power for fusion, and a controller analyzes reflected signals from the alignment targets to accurately align the laser with the prefabricated body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional 3D printing systems use a single high power level for fusion, then the fusion process is efficient, but precise alignment with prefabricated bodies cannot be achieved
Solution Approach 1:
The laser operation is segmented into two distinct power levels: a low power level for alignment and scanning operations, and a high power level for fusion operations. This segmentation allows the system to perform precise alignment measurements without the interference of high power fusion, thereby achieving both measurement precision and effective manufacturing
Solution Approach 2:
The system performs alignment and scanning operations at low power level before initiating the high power fusion process. By completing the alignment measurement phase in advance, the system ensures precise positioning of the energy beam relative to prefabricated bodies before material fusion begins
2Manufacturing precision
If the laser operates continuously at high power for fusion, then productivity is maintained, but alignment accuracy deteriorates
Solution Approach 1:
The laser system operates in periodic cycles, alternating between low power alignment/scanning phases and high power fusion phases. During each cycle, the laser first performs alignment measurements at low power, then transitions to high power for fusion operations. This periodic switching ensures that alignment accuracy is maintained while preserving overall manufacturing productivity through efficient cycle management
3Measurement precision
If alignment targets are not integrated into the carrier plate, then device complexity is reduced, but alignment precision cannot be achieved
Solution Approach 1:
The alignment targets are merged directly into the carrier plate structure, creating an integrated system where the carrier plate serves dual functions: holding prefabricated bodies and providing built-in alignment targets. This integration eliminates the need for separate alignment target components while achieving high measurement precision through the cross-hatch pattern embedded in the carrier plate
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
Enables precise alignment and fusion of layers onto prefabricated bodies, improving the accuracy and reliability of the 3D printing process by using a cross-hatch pattern and computational alignment techniques to determine target locations and adjust the laser system accordingly.
Implementation Method 1
receive a signal from the sensor; analyze the signal to align the radiation beam to the pre-fabricated body
Implementation Method 2
operate the vertical positioning apparatus, the laser system, and the powder dispenser to selectively form layers of metal over the prefabricated body
Implementation Method 3
selectively fuse layers of powder upon the pre-fabricated body in the build chamber
Data Source
Figure 1~2
Figure 3A~3B
Figure 4
AI summary
A three-dimensional printing system (2) for manufacturing a three-dimensional article (36) includes a build chamber (4), a carrier plate (6), a vertical positioning apparatus (32), a laser system (22), a sensor (26), a powder dispenser (28), and a controller (34). The carrier plate (6) defines a receptacle (10) and an alignment target (20). The receptacle (10) is for receiving and aligning a prefabricated body (12). The alignment target (20) is in precise lateral alignment with respect to the receptacle (10). The controller (34) is configured to: (1) operate the laser system (22) to generate and scan a radiation beam over an upper surface of the carrier plate (6); (2) concurrent with scanning the radiation beam, receive a signal from the sensor (26); (3) analyze the signal to align the radiation beam to the prefabricated body (12); and (4) operate the vertical positioning apparatus (32), the laser system (22), and the powder dispenser (28) to selectively form layers of metal over the prefabricated body (12) to complete manufacture of the three-dimensional article (36).