Laser Calibration via Light Reference Marks in Parallel Additive Manufacturing

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Solution Overview

Problem

Current additive manufacturing processes face challenges in precisely calibrating and synchronizing multiple laser devices due to temperature-related inaccuracies, which affect the quality and efficiency of parallel production in powder-bed-based systems.

Innovation Solution

An arrangement and method that uses marker devices to project light reference marks onto a build field, allowing for precise calibration and synchronization of laser devices by detecting these marks and adjusting their positions to compensate for thermally induced deformations, ensuring accurate and simultaneous operation of multiple laser devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple laser devices are used for parallel production, then productivity increases, but manufacturing precision deteriorates due to temperature-related inaccuracies

Engineering Contradiction:
Improveoutput rateVSAvoidpositional accuracy
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by performing calibration of multiple laser devices before parallel production using light reference marks. The system pre-establishes accurate positional relationships between laser devices and the build field, creating a calibrated state that compensates for thermal deformations during subsequent production. This preliminary calibration enables both high productivity through parallel processing and maintains manufacturing precision by addressing positioning accuracy before thermal effects accumulate.

Inventive Principle:
Principle #10Preliminary action

2Device complexity

If individual galvanometer scanners are adjusted for calibration, then device complexity is reduced, but manufacturing precision deteriorates because temperature-related inaccuracies of the entire system cannot be accounted for

Engineering Contradiction:
Improvecalibration system complexityVSAvoidsystem-wide positional accuracy
Core Design Contradiction:
Device complexityVSManufacturing precision

Solution Approach 1:

The patent introduces light reference marks as an intermediary element that mediates between the laser devices and the build field. These light reference marks serve as a common reference framework that all laser devices can use to establish accurate positional relationships. This intermediary approach enables system-wide calibration without requiring complex individual adjustments of each galvanometer scanner, maintaining both simplicity and high manufacturing precision across the entire parallel production system.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Productivity

If laser devices operate in parallel without precise calibration, then productivity increases through faster processing, but manufacturing precision deteriorates due to lack of synchronization

Engineering Contradiction:
Improveprocessing speedVSAvoidsynchronization accuracy
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

The patent replaces mechanical calibration and synchronization systems with an optical-based calibration system using light reference marks. Instead of relying on mechanical adjustments and synchronization of multiple laser devices, the system uses optical projection of light reference marks that all laser devices can detect and use for positioning. This substitution enables parallel operation at high speeds while maintaining precise synchronization and positional accuracy through optical rather than mechanical means.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

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

Enhances the positional accuracy and quality of manufactured components by compensating for operational inaccuracies, resulting in improved synchronization and increased output rates in parallel additive manufacturing processes.

Implementation Method 1

at least three marker devices (20), each capable of projecting a light reference mark (22) onto a component (100) lying on the build field (16) and/or onto the build field (16)

Methodology Applied
Scientific EffectLight projection: Light

Implementation Method 2

powder-bed-based additive manufacturing of a component... in which a material is added layer by layer and thermally processed to create a component

Methodology Applied
Scientific EffectLaser thermal processing: Laser

Implementation Method 3

melted by laser light... thermally processed to create a component

Methodology Applied
Scientific EffectThermal processing: Heating

Implementation Method 4

temperature-related inaccuracies... thermally induced deformations

Methodology Applied
Scientific EffectThermal deformation: Thermal Expansion

Data Source

PatentEP4282558B1Automated calibration of a device for fully parallel additive manufacturing of a component with combined working areas
Publication Date: 2025.05.21 RAYLASE GMBH
  • EP4282558B1 patent drawingFigure 1
  • EP4282558B1 patent drawingFigure 2
  • EP4282558B1 patent drawingFigure 3

AI summary

Arrangement (10) for powder bed-based additive manufacturing of a component (100), wherein the arrangement (10) comprises: a housing (12) comprising a build volume (14), the build volume (14) comprising a build area (16); at least three marker devices (20) attached in or to the housing (12), each marker device (20) being capable of projecting a light reference mark (22) onto a component (100) lying on the build area (16) and/or onto the build area (16); a plurality of laser devices (30) for laser processing of a powder bed to produce a component (100) on the build area (16) by means of additive manufacturing, wherein each laser device (30) is configured for laser processing of an associated work area (32a-32d), wherein each laser device (30) comprises a detection device (34) configured to detect the light reference markings (22);and a control unit (40) configured to calibrate and/or synchronize the laser devices (30) based on the light reference marks (22) detected by the detection device (34).