Multi-Beam Calibration Control for 3D Printing Cross Stitching
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Solution Overview
Problem
Current additively manufacturing apparatuses face challenges in calibrating multiple energy beams, leading to cross stitching errors and increased manufacturing time due to cumbersome and time-consuming calibration processes that do not account for influences during the additive manufacturing process.
Innovation Solution
Incorporating a calibration unit with sub-regions of different optical properties within the beam guiding plane, where energy beams generate calibration signals, and a determination device to assess these signals for alignment, allowing for real-time calibration and alignment of beam guiding units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple energy beams are used to irradiate build material, then manufacturing speed is improved, but cross stitching errors occur at beam guiding plane borders
Solution Approach 1:
The patent implements a feedback mechanism where calibration patterns are continuously monitored during the additive manufacturing process. Sensors detect the actual positions of calibration patterns irradiated by multiple energy beams, and this information is fed back to adjust beam guiding unit positions in real-time, eliminating cross stitching errors while maintaining high manufacturing speed
Solution Approach 2:
The patent performs preliminary calibration by irradiating calibration patterns at defined positions before actual manufacturing. The system pre-determines the correct positions and orientations of calibration patterns, storing this calibration data for use during manufacturing. This preliminary action ensures that when multiple energy beams operate simultaneously, they are properly aligned to prevent cross stitching errors at beam guiding plane borders
2Measurement precision
If traditional calibration processes are used with test specimens and coordinate measurement machines, then beam alignment can be verified, but the calibration process becomes cumbersome and time-consuming
Solution Approach 1:
The patent enables the apparatus to perform self-calibration by using built-in calibration patterns and integrated sensors instead of external coordinate measurement machines. The system automatically detects calibration pattern positions, calculates deviations, and adjusts beam guiding units without requiring removal of test specimens or external measurement equipment. This self-service approach maintains high calibration accuracy while dramatically reducing calibration time
Solution Approach 2:
The patent merges the calibration function with the manufacturing apparatus itself by integrating calibration patterns directly into the build plate and incorporating sensors within the apparatus. This consolidation eliminates the need for separate calibration equipment and processes, allowing calibration to be performed quickly in-situ without cumbersome external measurement machines or specimen removal
3Manufacturing precision
If calibration is performed in advance or after additive manufacturing, then initial alignment can be established, but thermal drift and other process influences cannot be compensated
Solution Approach 1:
The patent implements continuous calibration monitoring during the entire additive manufacturing process. Calibration patterns remain visible throughout manufacturing, and sensors continuously track their positions. This continuous action allows the system to detect and compensate for thermal drift and other process influences in real-time, maintaining calibration stability and manufacturing precision throughout the manufacturing cycle rather than only at initial or final stages
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 during the additive manufacturing process, reducing errors and manufacturing time by allowing for continuous monitoring and adjustment of beam alignment, thus improving the quality and speed of the manufacturing process.
Implementation Method 1
a plurality of calibration signals are generated by the plurality of sub-regions being irradiated with the plurality of energy beams
Data Source
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AI summary
An apparatus (1) for additively manufacturing three-dimensional objects (2) may include at least one calibration unit (11), at least one irradiation device (4), and a determination device (10). The least one calibration unit (11) may include at least one calibration region (14) arranged in the beam guiding plane (9), and the at least one calibration region (14) may include a plurality of sub-regions (15) differing in respect of at least one optical property. The at least one irradiation device (4) may be configured to guide a plurality of energy beams (7) across the at least one calibration region (14) comprising the plurality of sub-regions (15), and a plurality of calibration signals (20) may be generated by the plurality of sub-regions (15) being irradiated with the plurality of energy beams (7). The determination device (10) may be configured to determine the plurality of calibration signals (20) and to determine a calibration status of the irradiation device (4) based at least in part on the determined plurality of calibration signals (20).