Multi-LiDAR Array for Real-Time 3D Printing Defect Correction
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Solution Overview
Problem
Current 3D printing technologies lack effective real-time 3D image capture methods, leading to defects during the fabrication of objects, and existing LiDAR systems are large, heavy, and expensive, making them unsuitable for in-situ 3D imaging in additive manufacturing.
Innovation Solution
A method utilizing a plurality of LiDAR sensors spaced at specific angles around the deposition plane to scan and generate real-time 3D images of the printed object, comparing them to the 3D model to adjust the printer head and correct defects, with options for synchronous and asynchronous scanning modes to optimize sensor operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If scanning LiDAR systems with mechanical scanning are used to obtain 3D imaging, then 3D image capture is achieved, but the systems become large, heavy, expensive and unsuitable for in-situ imaging in AM/3DP systems
Solution Approach 1:
The patent replaces mechanical scanning systems with a multi-sensor array approach. Instead of using moving mechanical components to scan the object, multiple LiDAR sensors are positioned around the deposition plane to simultaneously capture 3D data from different angles, eliminating the need for large, heavy mechanical scanning systems while maintaining 3D imaging capability
Solution Approach 2:
The patent divides the 3D imaging function into multiple independent LiDAR sensors positioned at different locations (e.g., three sensors spaced 120 degrees apart, or six sensors spaced 60 degrees apart). Each sensor captures a portion of the object, and the data is combined to form a complete 3D image, replacing the need for a single complex mechanical scanning system
2Reliability
If real-time 3D image capture is implemented during 3D printing, then defects can be detected and corrected, but the system complexity and cost increase
Solution Approach 1:
The patent implements real-time monitoring by selectively activating LiDAR sensors based on the printing zone. Instead of continuously operating all sensors, the system activates only the sensors needed for the current printing location, reducing overall system complexity while maintaining real-time defect detection capability
Solution Approach 2:
The system continuously compares the scanned 3D object geometry with the intended 3D printable model and generates feedback signals that adjust the printer head in real-time to correct detected defects, enabling closed-loop control for improved printing reliability
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 real-time monitoring and correction of defects during 3D printing, reduces the size, weight, and cost of 3D imaging systems, and provides higher resolution and data accuracy for medium to large-sized 3D printers.
Implementation Method 1
LiDAR, which stands for Light Detection and Ranging, is a remote sensing method that uses laser light to measure ranges and distance
Implementation Method 2
Pulsed laser (PL) with time-of-flight measurement
Implementation Method 3
Continuous Wave (CW) laser with phase comparison
Implementation Method 4
3D printing relates to the process of creating a physical object from a 3D model. Typically, 3D printing relates to depositing many layers of material successively to build up the 3D object from the 3D model
Data Source
AI summary
A method for 3D printing an object, based on a 3D printable model of the object, includes scanning, by a first LiDAR sensor of a plurality of LiDAR sensors, a portion of the object while the object is being printed by a printer head. The method also includes generating an image of at least the portion of the object based on scanning the portion, generating a comparison by comparing the image with the 3D printable model, and sending a feedback signal that adjusts the printer head based on the comparison.