3D Printing Laser Beamlet Alignment Using Calibration Feedback
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Solution Overview
Problem
Additive manufacturing processes in 3D printing are characterized by long print times, low throughput, and lack of robustness and repeatability compared to traditional manufacturing methods, necessitating improvements for enhanced precision and accuracy.
Innovation Solution
A lasing module with optical assemblies, including lasers, mirrors, lenses, and imaging sensors, is used to steer laser beams accurately and precisely onto a build area, with a multi-stage alignment process to ensure all beamlets agree on a common coordinate space, utilizing calibration and alignment correction tables to maintain operational tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple lasers are used to increase manufacturing throughput, then productivity improves, but manufacturing precision deteriorates due to alignment difficulties between beamlets
Solution Approach 1:
The system divides the manufacturing task into multiple beamlets from separate lasers, each targeting specific regions of the build area. This segmentation enables parallel processing of different powder regions, increasing throughput while maintaining individual beamlet precision through separate calibration and alignment procedures for each laser source.
Solution Approach 2:
The system employs imaging sensors to capture images of the build area and uses image processing to determine actual positions of powder and previously formed structures. This feedback information is used to dynamically adjust and recalibrate laser beamlet positions, ensuring all beamlets converge on intended target locations with high precision despite manufacturing tolerances and thermal drift.
2Adaptability or versatility
If laser beams are steered to cover large build areas, then manufacturing versatility improves, but manufacturing precision deteriorates due to difficulty in maintaining alignment across different positions
Solution Approach 1:
The system uses imaging sensors positioned in three-dimensional space to capture images of the build area. By processing these images and calculating spatial relationships, the system determines precise positions and orientations of features across the entire build volume, enabling accurate laser positioning in multiple dimensions and maintaining precision across large build areas.
Solution Approach 2:
The system dynamically adjusts laser beam parameters including position, angle, and focus based on real-time image feedback. The imaging system detects variations in powder bed topology and previously formed structures, and the control system modifies beamlet parameters accordingly to maintain precise alignment and manufacturing quality across different regions of the build area.
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 solution enhances the precision and accuracy of 3D printing, reducing defects and improving manufacturing efficiency by ensuring all laser beams align to the same point within specified tolerances, thereby improving part quality and reducing manufacturing time.
Implementation Method 1
the laser beams melt powdered metal disposed in a build module of the 3D printing system
Implementation Method 2
the lasers selectively melt the powdered metal to form structures of the part
Data Source
AI summary
A method includes generating, for a first beamlet of a lasing module, first calibration data that represents a first position of first mirrors for directing a first laser beam of the first beamlet to a location within a build area, generating, for a second beamlet of the lasing module, second calibration data that represents a second position of second mirrors for directing a second laser beam of the second beamlet to the location, causing a third beamlet to output a third laser beam at the location, receiving, via a first imaging sensor of the first beamlet, first image data representing the third laser beam, receiving, via a second imaging sensor of the second beamlet, second image data representing the third laser beam, generating a first alignment correction table for directing the first laser beam, and generating a second alignment correction table for directing the first laser beam.