3D Laser Melting Quality Visualization for Melt Pool Deviations
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Solution Overview
Problem
Existing methods for monitoring and controlling selective laser melting processes lack effective visualization tools to easily evaluate component quality in real-time, making it difficult to ensure optimal fusion, temperature profiles, and component density during the building process.
Innovation Solution
A method and device that store sensor values with coordinate data and display them in 2D or 3D representations, allowing for real-time visualization of component regions with deviations from intended solidification or temperature values, using a visualization apparatus to highlight areas of concern during the laser melting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensor values are captured and stored with coordinate data for quality evaluation, then component quality assessment capability is improved, but device complexity increases
Solution Approach 1:
The patent creates a digital copy of the physical component by storing sensor values with their corresponding coordinate data. This digital representation allows quality assessment without adding physical measurement equipment to the manufacturing process. The visualization apparatus generates 2D or 3D representations that are copies of the actual component state, enabling evaluation while keeping the physical system relatively simple.
Solution Approach 2:
The patent introduces a visualization apparatus as an intermediary between the sensor data collection system and the user. This intermediary processes raw sensor values and coordinate data into meaningful 2D or 3D visual representations, reducing the complexity burden on both the data collection system and the user interface. The intermediary translates complex multidimensional data into intuitive visual forms that are easier to interpret.
2Speed
If real-time visualization of sensor values is implemented, then quality monitoring speed is improved, but processing requirements and system complexity increase
Solution Approach 1:
The patent implements partial visualization by allowing users to select specific component regions or parameters for display. Rather than visualizing all sensor data simultaneously, the system enables focused monitoring of critical areas or parameters. This partial action approach reduces processing requirements while maintaining effective quality monitoring speed for the most important parameters.
Solution Approach 2:
The patent segments the visualization into different views (2D representations, 3D representations, sectional planes) that can be independently configured and displayed. This segmentation allows the system to process and display only the necessary data for each view, reducing overall processing requirements while maintaining real-time monitoring capability for multiple aspects of component quality.
3Manufacturing precision
If detailed sensor data is stored and displayed for all component regions, then quality evaluation accuracy is improved, but data processing time and storage requirements increase
Solution Approach 1:
The patent applies local quality by allowing different levels of detail to be stored and displayed for different component regions. Critical areas with higher quality requirements can have more detailed sensor data stored and visualized, while less critical regions use coarser data representation. This approach maintains high quality evaluation accuracy where needed while reducing overall data processing time and storage requirements.
Solution Approach 2:
The patent performs preliminary filtering and organization of sensor data during the manufacturing process, storing only the most relevant quality parameters with their coordinate information. By pre-processing and selecting only essential data for storage rather than capturing all possible sensor measurements, the system reduces subsequent data processing time while maintaining sufficient accuracy for quality evaluation.
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 immediate identification of potential issues in component quality, such as reduced solidification or temperature deviations, allowing for adjustments during the process to prevent material failure and improve the accuracy of generated components.
Implementation Method 1
a laser, the focused laser beam of which impinges on the powder surface and causes the powder to melt within a melt zone
Implementation Method 2
by successive solidification of individual layers of building material which can be solidified by the action of radiation
Implementation Method 3
a detector for capturing electromagnetic radiation which is emitted or reflected by the powder surface and interacts with an optical system
Data Source
AI summary
A method for producing a three-dimensional component by means of a laser melting process, in which the component is produced by consecutively solidifying individual layers made of building material by melting the building material, wherein said building material can be solidified by the action of radiation, wherein the melting area produced by a punctiform and/or linear energy input is detected by a sensor device and sensor values are derived therefrom in order to evaluate the component quality. The sensor values detected in order to evaluate the component quality are stored together with the coordinate values that locate the sensor values in the component and are displayed by means of a visualization unit in two- and/or multi-dimensional representation with respect to the detection location of the sensor values in the component.