Multi-Beam Irradiation Calibration Using On-Axis Pattern Imaging
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Solution Overview
Problem
Current methods for calibrating irradiation devices used in additive manufacturing with multiple energy beams are cumbersome and time-consuming, relying on test specimens and manual analysis of calibration patterns, which complicates establishing the correct relation between irradiation units.
Innovation Solution
A method where one energy beam generates a calibration pattern in a determination region, and an on-axis determination unit images this pattern to determine its position, allowing for the generation of calibration information and adjustment of beam guiding units to ensure accurate alignment and positioning of both irradiation units within the same coordinate system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If test specimens are arranged in the process chamber for calibration, then calibration patterns can be irradiated and analyzed, but the calibration process becomes cumbersome and time-consuming
Solution Approach 1:
A calibration body with a calibration structure is introduced as an intermediary element. This calibration body is arranged in the process chamber and receives irradiation from the energy beams. The calibration structure on the calibration body interacts with the energy beams to generate detectable calibration patterns, serving as a mediator between the irradiation units and the determination units for accurate and efficient calibration
Solution Approach 2:
The manual arrangement and analysis process is replaced by an automated optical/electromagnetic detection system. Determination units detect the calibration patterns generated on the calibration body, automatically determining positions and generating calibration information without manual intervention, thereby reducing calibration time while maintaining precision
2Measurement precision
If manual analysis of calibration patterns is performed, then calibration information can be obtained, but the process becomes cumbersome
Solution Approach 1:
Manual analysis is replaced by automated determination units that optically or electromagnetically detect the calibration patterns on the calibration body. These units automatically determine positions and generate calibration information, eliminating the need for manual measurement and analysis while improving operational simplicity and accuracy
Solution Approach 2:
The calibration body with its specific calibration structure serves itself by generating detectable calibration patterns when irradiated. The determination units automatically read these patterns and extract calibration information without external intervention, making the calibration process self-service oriented and operationally simple
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 calibration of irradiation devices by directly determining and compensating for positional deviations between energy beams, ensuring accurate generation of calibration patterns and improving the alignment of coordinate systems, thus reducing stitching errors and enhancing the precision of three-dimensional object manufacturing.
Implementation Method 1
a first irradiation unit (3) is adapted to generate at least one first energy beam (6) and guide the first energy beam (6) via a first beam guiding unit (7) in a first guiding region in a build plane (8)
Implementation Method 2
a second irradiation unit (4) is adapted to generate at least one second energy beam (10) and guide the second energy beam (10) via a second beam guiding unit (11) in a second guiding region in a build plane (8)
Implementation Method 3
the at least one other beam guiding unit (7, 11) is adapted to image at least one part of the determination region (15) to an on-axis determination unit (12, 14) of the at least one other irradiation unit (3, 4)
Data Source
AI summary
Method for calibrating an irradiation device (2) for additively manufacturing three-dimensional objects which irradiation device (2) comprises at least two irradiation units (3, 4), comprising: guiding one of the at least two energy beams (6, 10) via the corresponding irradiation unit (3, 4) to a determination region (15), preferably a part of a build plane (8), for generating a calibration pattern (18, 19); imaging at least one part of the determination region (15) to an on-axis determination unit (12, 14) of the at least one other irradiation unit (3, 4); determining a position of the calibration pattern (18, 19) in the determination region (15) on basis of the image of the at least one part of the determination region (15); generating calibration information relating to a calibration status of at least one part of the irradiation device (2) based on the position of the calibration pattern (18, 19).