Laser Metal Deposition Alignment for Building on Existing Structures
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Solution Overview
Problem
Existing build systems face challenges in accurately constructing three-dimensional objects using powder-like materials with energy beams, particularly in aligning and integrating them with existing structures or repairing missing parts.
Innovation Solution
A build system and method that utilizes a processing system with a material supply apparatus, processing apparatus, and alignment mechanisms to form three-dimensional structural objects on a workpiece using Laser Metal Deposition, incorporating a material nozzle, irradiation optical system, and guide light emitting apparatuses to ensure precise alignment and integration with existing structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If powder-like materials are melted with an energy beam to build three-dimensional objects, then manufacturing capability is improved, but alignment precision with existing structures deteriorates
Solution Approach 1:
The patent applies preliminary action by performing alignment operations before the actual build process. The system calculates transformation matrices between coordinate systems of the existing structure and the build object in advance, and performs alignment using guide lights before material deposition begins. This ensures that the build object will be precisely positioned relative to the existing structure throughout the manufacturing process.
Solution Approach 2:
The patent uses guide lights as an intermediary tool to facilitate alignment between the build object and existing structure. The guide lights emit visible light along the energy beam path, allowing operators to visually verify alignment accuracy. This intermediary medium bridges the gap between the invisible energy beam and the visible workpiece, enabling precise alignment without directly affecting the manufacturing capability.
2Manufacturing precision
If alignment mechanisms are added to improve positioning accuracy, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent applies universality by designing the guide light emitting apparatus to serve multiple functions. The same guide lights are used for both alignment verification during the build process and for calculating transformation matrices between coordinate systems. This multi-functional approach improves positioning accuracy without requiring separate dedicated alignment devices, thereby avoiding increased device complexity.
Solution Approach 2:
The system applies self-service by using the existing build system components (energy beam apparatus, coordinate measurement systems) to perform alignment functions. The guide lights utilize the existing optical paths and coordinate systems of the build system, allowing the system to align itself without requiring external complex alignment equipment. This self-alignment capability improves positioning accuracy while maintaining device simplicity.
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 the formation of precise three-dimensional structural objects that can be integrated with or separate from existing structures, addressing alignment and integration challenges, and facilitating repairs by ensuring accurate positioning and material deposition.
Implementation Method 1
a build system that builds a build object by melting powder-like materials with an energy beam and then solidifying the molten materials
Implementation Method 2
form three-dimensional structural objects on a workpiece using Laser Metal Deposition
Data Source
Figure 1
Figure 2
Figure 3A~3J
AI summary
A build system is a build system that builds a build object on an object and is provided with a display apparatus that display an image relating to the object; and a build apparatus that builds the build object on the object on the basis of a designated position that is designated by using the image displayed by the display apparatus.