Multi-Laser Head Alignment Using Build-Platform Calibration Marks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In additive manufacturing systems, multiple laser heads used for fabricating components can become misaligned due to thermal effects on optical components, leading to improper component manufacturing if not correctly aligned.
Innovation Solution
The system employs a method to align laser heads using a build platform with calibration marks, where laser beams are directed and their scattering signals detected to generate intensity maps, which are compared to standard maps to align the laser heads, allowing for realignment during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple laser heads are used to manufacture components simultaneously, then productivity is improved, but alignment precision deteriorates due to thermal effects on optical components
Solution Approach 1:
The system performs preliminary alignment of multiple laser heads using calibration marks on the build platform before manufacturing begins. This preliminary alignment establishes a reference framework that compensates for thermal effects during the manufacturing process, allowing multiple laser heads to maintain precision while operating simultaneously.
Solution Approach 2:
The system uses optical sensors to detect scattering signals from calibration marks and continuously monitors laser head positions. This feedback mechanism allows the system to detect and correct alignment deviations caused by thermal effects during manufacturing, maintaining precision while achieving high productivity through parallel processing.
2Manufacturing precision
If laser heads are realigned during manufacturing, then alignment precision is maintained, but manufacturing time increases
Solution Approach 1:
The system performs preliminary alignment using calibration marks before manufacturing begins, establishing a reference framework that reduces the need for frequent realignment during manufacturing. This preliminary setup minimizes interruptions while maintaining precision.
Solution Approach 2:
The system replaces mechanical realignment procedures with optical detection and computational correction. Optical sensors detect scattering signals from calibration marks, and computing devices calculate alignment corrections, eliminating the need for manual mechanical adjustment during manufacturing and reducing manufacturing cycle time.
3Manufacturing precision
If complex alignment procedures are implemented, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The system uses the build platform itself as the calibration reference by incorporating calibration marks directly into the platform structure. This self-service approach eliminates the need for separate calibration fixtures or complex external alignment equipment, reducing device complexity while maintaining alignment precision.
Solution Approach 2:
The calibration marks on the build platform serve multiple functions: they provide alignment references for multiple laser heads, serve as measurement targets for optical sensors, and can be reused across different manufacturing campaigns. This multi-functionality reduces the need for specialized equipment, simplifying the overall system.
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 method ensures accurate alignment of laser heads and beams, enabling faster and cost-effective production of complex components by using existing hardware and allowing for quick realignment during the manufacturing process, thus maintaining component quality.
Implementation Method 1
The optical sensor is configured to detect a scattering signal of the laser beam generated by reflecting off of the plurality of calibration marks and the build platform
Implementation Method 2
The optical sensor is configured to detect a scattering signal of the laser beam generated by reflecting off of the plurality of calibration marks and the build platform
Data Source
AI summary
An additive manufacturing system includes a build platform and at least two laser heads. Each laser head includes at least one laser device, an optical sensor, and a computing device. The build platform includes a plurality of calibration marks. The laser device is configured to generate a laser beam. The laser beam is directed toward the plurality of calibration marks and the build platform. The optical sensor is configured to detect a scattering signal of the laser beam generated by reflecting off of the plurality of calibration marks and the build platform. The computing device is configured to receive the scattering signal from the optical sensor. The computing device is configured to align the laser heads such that the scattering signal aligns with the plurality of calibration marks and such that the laser heads align with each other.