Multi-Beam 3D Printing Calibration for Cross Stitching Alignment
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Solution Overview
Problem
Current additively manufacturing apparatuses face challenges in calibrating multiple energy beams across a beam guiding plane, leading to cross stitching errors due to misalignment, which are time-consuming and cumbersome, and do not account for influences during the manufacturing process, such as thermal drift.
Innovation Solution
Incorporating a calibration unit with sub-regions of differing optical properties within the beam guiding plane, where energy beams generate calibration signals that a determination device uses to assess and align the beams, allowing for real-time calibration and alignment of the energy beams during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple energy beams are used to irradiate build material, then productivity is improved by reducing manufacturing time, but manufacturing precision deteriorates due to cross stitching errors at beam guiding plane borders
Solution Approach 1:
The patent implements a feedback mechanism where calibration patterns are irradiated on the build plate, detected by a detection device, and used to generate correction values that adjust the beam guiding units. This closed-loop feedback system continuously monitors and corrects alignment deviations, ensuring that multiple energy beams maintain precise alignment at their guiding plane borders, thereby eliminating cross stitching errors while maintaining high productivity
Solution Approach 2:
The patent replaces manual mechanical calibration processes with an automated optical detection and correction system. Instead of physically adjusting beam guiding units through cumbersome manual procedures, the system uses optical detection of calibration patterns and automated calculation of correction values to substitute and adjust beam positions, significantly improving alignment precision while maintaining the benefits of multiple energy beams
2Manufacturing precision
If manual calibration processes are used to align beam guiding units, then manufacturing precision can be improved, but loss of time increases due to cumbersome and time-consuming calibration procedures
Solution Approach 1:
The patent implements preliminary action by automatically performing calibration procedures before actual manufacturing begins. The system pre-irradiates calibration patterns, detects their positions, calculates correction values, and applies adjustments to beam guiding units in advance. This preliminary automated calibration eliminates the need for time-consuming manual calibration during production setup, reducing calibration time while ensuring high alignment precision for subsequent manufacturing operations
Solution Approach 2:
The patent enables the system to perform self-calibration without external manual intervention. The apparatus automatically irradiates calibration patterns, detects their positions using integrated detection devices, calculates necessary corrections, and adjusts beam guiding units autonomously. This self-service calibration capability eliminates the need for operator involvement in time-consuming manual calibration processes, significantly reducing calibration time while maintaining high precision alignment
3Manufacturing precision
If calibration is performed in advance before manufacturing, then manufacturing precision can be established, but adaptability deteriorates as thermal drift and other influences during manufacturing cannot be accounted for
Solution Approach 1:
The patent implements continuous feedback during manufacturing operations where calibration patterns are repeatedly irradiated and detected, and correction values are continuously calculated and applied based on real-time alignment measurements. This ongoing feedback mechanism allows the system to detect and compensate for thermal drift and other environmental influences that occur during manufacturing, maintaining high alignment precision and adaptability throughout the entire manufacturing process rather than relying solely on initial pre-manufacturing calibration
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 approach enables efficient and accurate calibration of energy beams, reducing cross stitching errors and allowing for continuous monitoring and adjustment during the additive manufacturing process, thereby improving the quality and efficiency of the manufacturing process.
Implementation Method 1
at least one irradiation device (4) configured to guide a plurality of energy beams (7, 8) across the at least one calibration region (14)
Data Source
AI summary
An apparatus for additively manufacturing three-dimensional objects may include at least one calibration unit, at least one irradiation device, and a determination device. The least one calibration unit may include at least one calibration region arranged in the beam guiding plane, and the at least one calibration region may include a plurality of sub-regions differing in respect of at least one optical property. The at least one irradiation device may be configured to guide a plurality of energy beams across the at least one calibration region comprising the plurality of sub-regions, and a plurality of calibration signals may be generated by the plurality of sub-regions being irradiated with the plurality of energy beams. The determination device may be configured to determine the plurality of calibration signals and to determine a calibration status of the irradiation device based at least in part on the determined plurality of calibration signals.