Laser Beam Sampling for In-Process Additive Manufacturing Analysis
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Solution Overview
Problem
Current additive manufacturing systems face challenges in accurately detecting and controlling beam data, such as beam power, position, and diameter, during the manufacturing process due to the inaccessibility of the processing plane, leading to inconsistencies in component quality and precision.
Innovation Solution
A method and device that position a beam barrier and a beam sampling module in the beam path to direct a portion of the energy beam to a measuring device with a radiation detector, allowing for the determination of beam data during the manufacturing process without obstructing the beam path, and using this data for real-time process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a measuring device is placed directly in the processing plane to detect beam data, then measurement precision is improved, but the device complexity and obstruction of beam path increase
Solution Approach 1:
A beam sampling module is introduced as an intermediary component that extracts a portion of the beam energy to redirect to the measuring device. This allows the main beam path to remain unobstructed while enabling accurate beam parameter measurements through the sampled portion, resolving the contradiction between measurement precision and beam path obstruction.
Solution Approach 2:
The beam energy is segmented into two portions: the main beam continues to the processing plane for manufacturing, while a sampled portion is diverted to the measuring device for detection. This segmentation allows simultaneous operation of processing and measurement without mutual interference, improving measurement precision without complicating the overall system architecture.
2Manufacturing precision
If beam data is monitored in real-time during manufacturing, then manufacturing precision is improved, but the production time increases due to additional measurement steps
Solution Approach 1:
The beam sampling and measurement process occurs continuously during the manufacturing operation without interrupting the beam's processing function. The sampling module extracts beam data in real-time while the main beam continues solidifying the construction material, ensuring manufacturing precision is maintained without extending production time.
Solution Approach 2:
Beam parameter measurements are performed preliminarily during layer application or between layers rather than after complete manufacturing. This allows detection of beam variations before they affect component quality, enabling corrective actions without extending the overall production cycle time.
3Ease of operation
If the processing plane is made accessible for measurement, then ease of operation is improved, but the reliability of the manufacturing process deteriorates due to potential contamination or interference
Solution Approach 1:
The beam sampling module serves as an intermediary that enables measurement functionality without requiring direct access to the processing plane. By sampling the beam in the beam path before it reaches the processing area, the system maintains ease of operation for measurements while preserving process reliability through isolation of the processing plane from external interference.
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 accurate and real-time monitoring and control of beam data, improving the precision and consistency of component production by allowing for online detection and correction of beam-related issues without extending the production time or altering the manufacturing process.
Implementation Method 1
A beam sampling module 20 is positioned in the beam path between the beam deflecting device (40) and a selected processing coordinate (44) on the processing plane (45). At least a portion of the beam directed by the beam deflecting device (40) towards the selected processing coordinate (44) is directed to a measuring device (10).
Implementation Method 2
At least a portion of the beam directed by the beam deflecting device (40) towards the selected processing coordinate (44) is directed to a measuring device (10) having a radiation detector (12).
Data Source
AI summary
The invention relates to a method and a device for the analysis of energy beams in systems for the additive manufacture of components (70) by means of layered solidification of a construction material (55) by an energy beam (30). The invention enables a determination of position-related beam data directly with respect to the processing point during the machining process. An additive manufacturing system includes a beam deflecting device (40), a processing plane (45), and a layer applicator (60). The device according to the invention comprises a movable beam barrier (17), a movable beam sampling module (20) and a measuring device (10) with a radiation detector (12).