Optical Working Beam Scanning for Precise Powder Bed Area Detection
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Solution Overview
Problem
Existing generative manufacturing devices face challenges in accurately determining the position of a preform within the working area due to inaccuracies in measuring devices and registration errors between the measuring device and the scanner, which affect the quality and precision of hybrid component production.
Innovation Solution
The method involves scanning an optical working beam across the working area, detecting remitted light along the optical axis, and obtaining an image from location-dependent signal values, eliminating the need for separate measuring devices and registration accuracy, thus allowing precise detection of the working area without material alteration or additional sensor components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If separate measuring devices are used to detect the working area, then measurement capability is provided, but device complexity and cost increase
Solution Approach 1:
The optical working beam is used for dual purposes: both for material processing (generative manufacturing) and for detecting the working area. The same beam delivery system and scanner are utilized for both functions, eliminating the need for separate measuring devices and reducing system complexity while maintaining measurement capability
Solution Approach 2:
The system uses its own optical working beam to detect the working area instead of requiring external measuring devices. The beam serves the system itself by providing measurement functionality through the existing optical infrastructure, making the system self-sufficient
2Measurement precision
If separate measuring devices are used to detect the working area, then measurement capability is provided, but cost increases
Solution Approach 1:
The optical working beam performs dual functions of material processing and area detection, eliminating the need to purchase and integrate separate measuring devices, thereby reducing overall system cost while maintaining measurement precision
Solution Approach 2:
The system utilizes its existing optical infrastructure for self-detection, avoiding additional investment in external measuring equipment while still achieving accurate position detection of the working area
3Measurement precision
If high optical output power is used for detection, then detection capability is improved, but material alteration occurs
Solution Approach 1:
The optical output power is dynamically adjusted based on the detection task requirements. Lower power levels are used for working area detection to avoid material alteration, while higher power is reserved for actual generative manufacturing processes, thus achieving detection without harmful effects
4Measurement precision
If registration between measuring device and scanner is required, then separate measurement is enabled, but registration accuracy issues arise
Solution Approach 1:
The detection function is merged with the existing scanner system. The same scanner that positions the optical working beam for manufacturing is used to scan and detect the working area, eliminating registration issues between separate devices since there is only one scanning system
Solution Approach 2:
The scanner serves dual purposes: positioning the beam for generative manufacturing and scanning the working area for detection. This multi-functionality eliminates the need for registration between separate measuring devices and the scanner, as they are the same device
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 precise and cost-effective detection of the working area with high accuracy, allowing generative components to be built on preforms with minimal offset, using existing device components and control software, thus improving the quality and efficiency of hybrid component manufacturing.
Implementation Method 1
detecting signal values of light of the optical working beam remitted along an optical axis of the optical working beam
Data Source
AI summary
Methods for detecting a working area of a generative manufacturing device and manufacturing devices for generatively manufacturing components from a powder material are disclosed. The methods include scanning of an optical working beam of the generative manufacturing device in the working area, detecting signal values of remitted light of the optical working beam traveling along an optical axis of the optical working beam in a location-dependent manner, wherein a signal value is assigned to each location of the scan of the optical working beam in the working area, and obtaining an image of the working area from the location-dependent detected signal values. The optical working beam for detecting the working area is operated with an optical output power that is reduced compared to a lower power limit for the optical output power of the optical working beam used during generative manufacturing.