In-situ Laser Alignment Detection for Additive Manufacturing
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Solution Overview
Problem
In direct metal laser melting (DMLM) additive manufacturing, misalignment of multiple lasers can lead to seams or material defects in the built parts, as existing methods lack real-time alignment detection and correction capabilities.
Innovation Solution
An in-situ field alignment system using a camera to capture images of laser strikes and compare their positions to expected alignments, with a processor-based alignment apparatus to determine misalignment and adjust the laser channels accordingly, ensuring proper calibration and alignment during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple lasers are used to increase productivity, then manufacturing speed and output are improved, but alignment between lasers becomes difficult to maintain and measure
Solution Approach 1:
A camera system is introduced as an intermediary device to capture images of laser strikes on the build platform. The camera serves as a mediator between the multiple lasers and the alignment measurement process, enabling non-contact detection of laser positions and facilitating precise alignment measurement without interfering with the manufacturing process.
Solution Approach 2:
The patent replaces mechanical alignment measurement methods with an optical imaging system. Instead of using physical gauges or mechanical contact methods to measure laser alignment, the system uses a camera to capture images of laser strikes and processes these images computationally to determine alignment, thereby eliminating mechanical interference and improving measurement precision.
2Manufacturing precision
If real-time alignment monitoring is implemented to improve quality, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The camera system serves multiple functions: it captures images for alignment measurement, records the position of laser strikes, and provides data for both quality control and process documentation. This multi-functionality reduces the need for separate specialized devices, thereby limiting the increase in overall system complexity while achieving real-time alignment monitoring.
Solution Approach 2:
The system uses the existing build platform and laser strike marks as part of the measurement process. The laser strikes themselves serve as the measurement targets, eliminating the need for separate calibration targets or additional reference structures. The system essentially uses the manufacturing process elements themselves to perform the alignment measurement.
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
The system effectively prevents material defects by continuously monitoring and correcting laser alignment in real-time, ensuring accurate stitching and quality of the built parts.
Implementation Method 1
capture images of laser strikes made by the lasers on the build plane
Data Source
AI summary
An apparatus may include a processor, memory modules, and machine-readable instructions stored in the memory modules. When executed by the processor, the instructions may cause the apparatus to receive image data of one or more laser strikes on a build plane, the image data indicating positions of a first set of fiducial strikes made by a first laser on the build plane and positions of a second set of fiducial strikes made by a second laser on the build plane, determine relative positions of the first set of fiducial strikes and the second set of fiducial strikes with respect to each other from the received image data, compare the determined relative positions of the first and second sets of fiducial strikes with respect to each other to expected relative positions of the first and second sets of fiducial strikes with respect to each other, and determine whether the first laser and the second laser are misaligned with respect to each other based on the comparison.