Layer Defect Analysis for In-Process Additive Manufacturing Correction

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Solution Overview

Problem

Current additive manufacturing processes face challenges in detecting and correcting defects in real-time, leading to waste and increased costs due to internal defects and machine calibration issues.

Innovation Solution

A system and method that integrates a defect analysis subsystem with an additive manufacturing device to monitor sequential layers for defects, determine if correction is needed, identify correction parameters, and send commands to the device to perform correction procedures during the build process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If real-time defect detection and correction is implemented during additive manufacturing, then manufacturing precision and productivity are improved, but device complexity increases

Engineering Contradiction:

Improvedefect detection accuracyVSAvoidsystem complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The defect analysis subsystem is nested within the additive manufacturing device, with the controller integrated into the existing system architecture. The monitoring device is positioned to observe the build chamber through existing access points, and correction commands are routed through the device's existing control interfaces, minimizing additional system complexity while enabling real-time defect detection and correction

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The controller acts as an intermediary between the monitoring device and the additive manufacturing device actuators. It receives defect information from the monitoring device, processes this data to determine appropriate corrections, and sends commands to the device to execute corrections, thereby managing system complexity through a centralized control layer

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If continuous monitoring of sequential layers is performed, then manufacturing precision is improved, but use of energy and time increase

Engineering Contradiction:

Improvedefect detection capabilityVSAvoidbuild time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The monitoring device operates continuously throughout the additive manufacturing process, observing each sequential layer as it is deposited. This continuous monitoring enables immediate detection of defects without interrupting the build process, maintaining manufacturing precision while minimizing time loss through real-time rather than post-build inspection

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system rapidly processes monitoring data and executes corrections during brief intervals between layer deposits or within the same layer cycle. By rushing through the detection and correction cycle within the existing manufacturing timeline, the system minimizes additional time expenditure while maintaining continuous oversight

Inventive Principle:

Principle #21Skipping (Rushing through)

3Productivity

If real-time correction procedures are executed, then productivity is improved by reducing scrap, but device complexity and operational complexity increase

Engineering Contradiction:

Improveproduction efficiencyVSAvoidoperational simplicity

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The additive manufacturing device performs self-correction by executing remediation actions autonomously based on defect detection. The controller automatically determines appropriate correction parameters and commands the device to adjust process parameters or reprocess affected areas, reducing the need for manual intervention and simplifying operation while improving productivity through reduced scrap

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system implements a closed-loop feedback mechanism where defect detection information from the monitoring device is continuously fed back to the controller, which then adjusts process parameters or triggers correction procedures. This automated feedback loop simplifies operation by eliminating manual defect assessment and decision-making, allowing the system to self-regulate and improve productivity through reduced rework and scrap

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS12280429B2Systems and methods for defect detection and correction in additive manufacturing processes

Publication Date: 2025.04.22 SENTIENT SCIENCE CORP

AI summary

A system and method of additive manufacturing is disclosed herein which when run or performed form a product with a powder-based additive manufacturing device by adding sequential layers of material on top of one another. As each sequential layer of material is added, the system and method can include monitoring the sequential layer with a defect analysis subsystem to detect whether the sequential layer has any defects. For a detected defect, it can be determined whether defect correction is required. For a required defect correction, one or more correction parameters for the required defect correction can be identified; and a correction command including the one or more correction parameters can be sent to the additive manufacturing device, the correction command causing the additive manufacturing device to help correct the detected defect in the sequential layer according to the correction parameters prior to moving on to a next sequential layer.