3D Printing Laser Calibration via Partially Reflective Mirror
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Solution Overview
Problem
Three-dimensional printing systems using lasers face challenges in alignment and calibration, particularly during new laser installations and over time, leading to quality loss and high maintenance costs.
Innovation Solution
A three-dimensional printing system with a laser module, scan module, and controller that includes a motorized mirror with an optical coating and sensors to analyze calibration errors, allowing for automatic adjustment of pitch, yaw, and focus to maintain precise alignment and focus of the light beam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment and calibration by highly trained technicians is used, then initial setup precision is improved, but maintenance cost and complexity increase
Solution Approach 1:
The system performs automatic self-calibration using a sensor to detect the laser beam position and a controller to adjust mirror angles, eliminating the need for manual intervention by trained technicians while maintaining high precision alignment
Solution Approach 2:
The calibration system uses a sensor to detect the laser beam position and provides feedback to the controller, which automatically adjusts the motorized mirror angles to correct alignment errors, creating a closed-loop system that maintains precision without manual intervention
2Measurement precision
If manual calibration is performed periodically, then alignment precision can be restored, but production time is lost and productivity decreases
Solution Approach 1:
The calibration system operates continuously or periodically without interrupting the manufacturing process, maintaining laser alignment precision while keeping production flowing uninterrupted
Solution Approach 2:
The system automatically performs calibration adjustments during or between production cycles without requiring manual intervention, restoring alignment precision without stopping production
3Use of energy by moving object
If a highly reflective mirror coating is used, then laser beam transmission to build plane is improved, but calibration detection sensitivity decreases
Solution Approach 1:
The system uses a partially reflective mirror coating that acts as an intermediary, reflecting most of the laser beam for efficient transmission to the build plane while transmitting a small portion to the sensor for calibration detection
Solution Approach 2:
The mirror coating is designed with specific reflectivity parameters (90-98% reflection, 2-10% transmission) that optimize both laser beam transmission efficiency and calibration detection sensitivity simultaneously
4Ease of repair
If automatic calibration system is implemented, then maintenance cost is reduced, but device complexity increases
Solution Approach 1:
The system automatically performs calibration adjustments using a sensor to detect beam position and a controller to adjust motorized mirrors, reducing maintenance costs by eliminating the need for highly trained technicians while keeping the system relatively simple
Solution Approach 2:
The system replaces manual mechanical adjustment procedures with an automated optical-electrical system using sensors and motorized mirrors, reducing maintenance complexity while achieving precise automatic calibration
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 reduces the need for highly trained technicians and minimizes maintenance costs by enabling automatic calibration and alignment, ensuring consistent high-quality manufacturing of three-dimensional articles.
Implementation Method 1
The motorized mirror includes a substrate having an optical coating that reflects at least 90% of incoming beam power
Implementation Method 2
The sensor is positioned to receive transmitted light from the motorized mirror
Data Source
AI summary
A three-dimensional printing system is configured to selectively solidify a build material at a build plane in a layer-by-layer manner. The three-dimensional printing system includes a laser module, a scan module, and a controller. The laser module is for emitting a light beam along a main optical path from the laser module to the build plane. The scan module includes a motorized mirror and a sensor. The motorized mirror includes a substrate having an optical coating that reflects at least 90% of incoming beam power such that the mirror transmits no more than 10% of the incoming beam power. The sensor is positioned to receive transmitted light from the mirror. The controller is configured to operate the laser module to emit the light beam along the main optical path, analyze a signal from the sensor, and based upon the analysis, to estimate a calibration error for the laser module.