Long-Range 3D Scanning for Precise Printed Part Alignment
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Solution Overview
Problem
Conventional additive and subtractive manufacturing processes face challenges in precisely locating large, arbitrarily-shaped 3D printed objects for post-processing, often resulting in human error and potential damage due to the difficulty in detecting and aligning such objects in machine space, especially when they lack prominent geometry or have been moved.
Innovation Solution
The implementation of a system using structured light scanners or laser scanning with a support system to autonomously scan and locate 3D objects in machine space, employing long-range scanners for large objects and fiducial markers to create a precise 3D model, allowing for accurate alignment and translation of virtual coordinates to physical machine space without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual touching off is used to locate 3D objects, then the process is simple to operate, but measurement precision deteriorates due to human error
Solution Approach 1:
The patent replaces manual mechanical touching off with an automated optical scanning system. A scanner captures images of the 3D object and fiducial markers, and a computer automatically processes these images to determine precise location and orientation, eliminating human error while maintaining operational simplicity through automation.
Solution Approach 2:
The patent introduces fiducial markers as intermediary reference objects placed on the 3D object. These markers serve as mediators between the object and the scanning system, providing easily detectable geometric features that enable precise automated location without requiring manual measurement or prominent geometry on the object itself.
2Measurement precision
If automated scanning is implemented, then measurement precision improves, but device complexity increases
Solution Approach 1:
The patent employs a scanner that can function in multiple modes - it can scan both the fiducial markers and the 3D object itself, and the same system works for various object sizes and shapes. The computer software also performs multiple functions including image processing, feature detection, and coordinate calculation, reducing the need for separate specialized devices.
Solution Approach 2:
The patent creates a digital copy or representation of the physical 3D object through scanning. The scanner captures optical information and the computer processes this into a digital model with precise location data, allowing virtual manipulation and measurement without complex physical measurement apparatus.
3Measurement precision
If fiducial markers are used, then measurement precision improves, but ease of operation worsens due to additional setup steps
Solution Approach 1:
The patent applies fiducial markers to the 3D object before scanning. This preliminary action prepares the object in advance for automated detection, ensuring that the scanning system has reference features to work with. The markers are applied once during setup, enabling all subsequent scans to be performed automatically without repeated manual intervention.
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
This solution enables precise and automated location of 3D objects during post-processing, reducing human error and ensuring accurate alignment, even for complex or deformed large-scale structures, thereby enhancing the efficiency and reliability of additive and subtractive manufacturing processes.
Implementation Method 1
The scanner 300 can include a light source configured to emit light toward the printed object 201 and a detector configured to detect light reflected from the printed object 201
Implementation Method 2
The implementation of a system using structured light scanners or laser scanning with a support system to autonomously scan and locate 3D objects in machine space
Data Source
AI summary
A system for part location and long-range scanning of large additively manufactured structures and method for using the same. In some embodiments, the method for locating and scanning a three-dimensional (3D) object comprises scanning a first portion of the 3D object from a first position via a long-range scanner on a mobile platform, determining whether additional portions of the 3D object require scanning, moving the long-range scanner via the mobile platform to a second position based on said determination that additional portions of the 3D object require scanning, and aligning each portion of the scanned 3D object.