Optical Work Beam Imaging for Precise Powder Bed Alignment
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Solution Overview
Problem
Existing additive manufacturing systems face inaccuracies in determining the position of a preform within the work area due to registration errors between measuring devices and scanners, leading to misalignment and reduced quality of hybrid components.
Innovation Solution
Utilize the optical work beam itself for detecting the work area by capturing reflected light along its axis, eliminating the need for separate measuring devices and directly obtaining images in the scanner's coordinate system, thus enhancing positional accuracy and eliminating registration errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If separate measuring devices are used to determine preform position, then position detection capability is provided, but registration errors occur between measuring device and scanner coordinate systems
Solution Approach 1:
The patent merges the measuring function into the existing optical work beam system by detecting reflected light from the work beam itself. This eliminates the need for separate measuring devices and their associated coordinate system transformations, directly achieving both position detection and scanner coordinate system compatibility.
Solution Approach 2:
The optical work beam serves dual functions: it performs both the additive manufacturing process and the position detection function by capturing reflected light. This multi-functionality eliminates the need for dedicated measuring devices and their complex registration procedures.
2Measurement precision
If additional measuring devices are integrated into the additive manufacturing system, then position monitoring capability is enhanced, but device complexity and cost increase
Solution Approach 1:
The existing optical work beam is made multi-functional by adding the capability to detect reflected light for position determination. This eliminates the need for additional measuring devices, sensors, or separate detection systems, thereby reducing device complexity while maintaining measurement precision.
Solution Approach 2:
The optical work beam serves itself by providing both the manufacturing function and the measurement function. The system uses its own work beam for detection purposes, eliminating the need for external or additional measuring devices.
3Productivity
If high optical output power is used for work beam, then additive manufacturing process is effective, but material damage or unwanted changes occur in the work area
Solution Approach 1:
For position detection, only a small portion of the reflected light from the work beam is captured and analyzed. The work beam operates at full power for manufacturing, but the detection function uses only the reflected light portion, avoiding the need to reduce overall beam power while still preventing material damage during detection.
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
Achieves precise and cost-effective detection of the work area without additional sensors, allowing for high-accuracy alignment of preforms and additively manufactured components, simplifying implementation and reducing errors.
Implementation Method 1
Signal values of light reflected along an optical axis of the optical work beam are detected as a function of location
Data Source
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AI summary
The invention relates to a method for capturing a working region (7) of a generative manufacturing device (1), comprising the following steps: moving an optical working beam (5) of the generative manufacturing device (1) in the working region (7); location-dependent capturing of signal values of light (15) from the optical working beam (5) returned along an optical axis (A) of the optical working beam (5), wherein a signal value is associated with each location (11) of the shifting of the optical working beam (5) in the working region (7); and obtaining an image of the working region (7) from the signal values captured in a location-dependent manner. The method is characterised in that the optical working beam (5) for capturing the working region (7) is operated at an optical output power which is reduced by comparison with a lower power limit for the optical output power of the optical working beam (5) for generative manufacturing.