Multi-Laser Irradiation Calibration for Stitching Accuracy in 3D Printing
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Solution Overview
Problem
Current methods for calibrating irradiation devices in additive manufacturing are cumbersome and time-consuming, requiring test specimens and manual analysis of calibration patterns to establish the relation between multiple irradiation units, leading to potential stitching errors and deviations in object geometry.
Innovation Solution
A method where one energy beam is guided to a determination region to generate a calibration pattern, which is then imaged by another irradiation unit 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 energy beams 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 the relation between irradiation units can be established, but the calibration process becomes cumbersome and time-consuming
Solution Approach 1:
The patent uses a camera to capture optical images of calibration patterns on the test specimen, creating a digital copy that can be analyzed without manual measurement. This allows the calibration data to be extracted automatically from the captured image, significantly reducing the time required while maintaining measurement precision
Solution Approach 2:
The patent replaces manual mechanical measurement and analysis of calibration patterns with automated optical imaging and computer-based analysis. The camera system and software automatically determine positions and calculate deviations, eliminating the need for time-consuming manual inspection and analysis
2Measurement precision
If manual analysis of calibration patterns is performed, then calibration can be verified, but the process becomes cumbersome and time-consuming
Solution Approach 1:
The system performs self-calibration by automatically capturing images of the calibration patterns and computing the positions and deviations using image processing algorithms. The calibration process serves itself without requiring manual intervention for measurement and analysis, improving both ease of operation and maintaining verification accuracy
Solution Approach 2:
The patent implements an automated feedback mechanism where the camera captures calibration pattern positions, the system calculates deviations from expected positions, and this information is used to adjust and verify the calibration of irradiation units. This closed-loop feedback system automates the verification process while maintaining high accuracy
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 the position of calibration patterns and compensating for deviations, ensuring accurate alignment and reducing the likelihood of stitching errors, thereby improving 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 (15) of 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 (15) of a build plane (8)
Data Source
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AI summary
Method for calibrating an irradiation device (2) of an apparatus (1) for additively manufacturing three-dimensional objects by means of successive layerwise selective irradiation and consolidation of layers of a build material which can be consolidated by means of an energy beam (6, 10), which irradiation device (2) comprises at least two irradiation units (3, 4), wherein 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 of a build plane (8), wherein 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 of a build plane (8), comprising the steps: - 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).