Multilaser Build-Plane Sensing for Sensor Deconfliction

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Solution Overview

Problem

Existing additive manufacturing processes lack effective non-destructive methods for verifying the quality and integrity of parts, as conventional quality assurance testing often requires destruction of the part.

Innovation Solution

The use of multiple photodetectors arranged radially around a central region of an additive manufacturing system to cooperatively monitor the build plane, allowing for redundancy and enhanced accuracy, along with the implementation of on and off-axis optical sensors to accurately monitor energy applied by multiple energy sources.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If multiple photodetectors are arranged radially around the build plane to cooperatively monitor energy radiated from multiple energy sources, then measurement precision and reliability are improved, but device complexity increases

Engineering Contradiction:

Improveaccuracy of energy monitoringVSAvoidsensor assembly complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The monitoring system is divided into multiple independent photodetector units arranged radially around the build plane. Each photodetector monitors a specific sector, and their signals are combined to achieve complete coverage. This segmentation allows the system to achieve high measurement precision through multiple measurements while managing complexity by using identical, standardized sensor units.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple photodetector signals are merged and combined by a processor to create a comprehensive monitoring picture of the entire build plane. The individual measurements from radially distributed sensors are integrated to achieve complete energy monitoring coverage, improving overall measurement precision while sharing common processing infrastructure.

Inventive Principle:

Principle #5Merging (Combining)

2Productivity

If multiple energy sources operate simultaneously on overlapping regions of the build plane, then productivity is improved, but sensor deconfliction becomes more difficult

Engineering Contradiction:

Improvemanufacturing throughputVSAvoidsensor deconfliction complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system continuously monitors energy radiated from the build plane and uses this feedback to identify and deconflict signals from multiple overlapping energy sources. The processor analyzes signals from multiple photodetectors to distinguish between different energy sources and their respective process zones, enabling simultaneous operation of multiple sources while maintaining accurate monitoring.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The processor acts as an intermediary that receives and processes signals from multiple photodetectors, deconflicting the data to identify which energy source is active in each region. This intermediary processing layer enables multiple energy sources to operate simultaneously on overlapping regions by mediating the information flow and distinguishing between different energy inputs.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Measurement precision

If conventional quality assurance testing is used to verify part integrity, then measurement precision is improved, but the part is destroyed

Engineering Contradiction:

Improvequality verification accuracyVSAvoidpart availability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The system performs preliminary monitoring of the additive manufacturing process in real-time, tracking energy input and material deposition as they occur. This preliminary action during manufacturing allows for early detection of defects and process deviations, enabling quality verification without needing to destroy the finished part for inspection.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces mechanical destructive testing with optical monitoring. Instead of physically examining or destroying the part to verify quality, the system uses photodetectors to monitor energy radiated during the additive manufacturing process, substituting mechanical testing with non-contact optical measurement that preserves the part.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical 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 approach enables non-destructive verification of part integrity and quality, improving accuracy and reducing the risk of part disqualification due to transient sensor outages, while allowing for real-time process control and adjustment.

Implementation Method 1

multiple photodetectors arranged radially around a central region of an additive manufacturing system to cooperatively monitor the build plane

Methodology Applied

Scientific EffectPhotoelectric Effect: Photoelectric Effect

Data Source

PatentUS12337523B2Sensor deconfliction in multilaser additive manufacturing systems

Publication Date: 2025.06.24 DIVERGENT TECHNOLOGIES INC

AI summary

This disclosure describes an additive manufacturing system that includes a build plane having a first region and a second region. Multiple energy source can be positioned above the build plane and configured to direct energy into the first and second regions of the build plane. The system includes optical sensors configured to monitor an intensity of light emitted from the energy sources. A processor associated with the additive manufacturing system is configured to adjust the sensor outputs in response to the energy sources coming into close proximity.