Optical Build Plane Measurement for Additive Manufacturing Alignment
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Solution Overview
Problem
Existing additive manufacturing machines face challenges due to deviations in the position of the energy beam generating device relative to the build plane, affecting the quality of manufactured components, necessitating improved systems and methods to maintain alignment and accuracy.
Innovation Solution
A position measurement system is integrated into the additive manufacturing machine to determine the position of the build plane relative to a reference plane, allowing for calibration and adjustment of the reference plane to ensure precise alignment and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the energy beam generating device is positioned relative to the build plane without a measurement system, then the device complexity is reduced, but the manufacturing precision deteriorates due to deviations from the reference position
Solution Approach 1:
The patent replaces complex mechanical measurement systems with optical measurement methods. A laser projector projects measurement beams onto the build plane, and cameras capture the reflected light to calculate positions. This optical substitution eliminates the need for complex mechanical contact sensors while achieving high positioning accuracy for the energy beam generating device.
Solution Approach 2:
The patent introduces an intermediary measurement system consisting of lasers, cameras, and computational algorithms. This intermediary system acts as a mediator between the energy beam generating device and the build plane, providing indirect but highly accurate position information without requiring direct mechanical contact or complex alignment mechanisms.
2Manufacturing precision
If the reference plane position is fixed without adjustment capability, then the device complexity is reduced, but the manufacturing precision deteriorates when deviations occur
Solution Approach 1:
The patent implements a feedback mechanism where the position measurement system continuously monitors the build plane position, compares it with the reference plane, and provides correction data. This feedback loop enables dynamic adjustment of the reference plane or energy beam positioning to compensate for deviations, maintaining high manufacturing precision without requiring overly complex mechanical adjustment mechanisms.
Solution Approach 2:
The patent transitions from a static reference plane to a dynamic system where the reference plane position can be adjusted based on real-time measurements. The system adapts to position deviations by dynamically recalibrating the reference frame or adjusting the energy beam generating device position, ensuring continuous alignment accuracy throughout the manufacturing process.
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 system enhances precision and accuracy in additive manufacturing by mitigating deviations, improving the quality of manufactured objects and maintaining dimensional tolerances within +/- 50 µm or less.
Implementation Method 1
detecting one or more properties of the energy beam upon having been reflected from the build plane
Data Source
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AI summary
An additive manufacturing machine (100) includes an energy beam system (132) situated in a fixed position relative to a reference plane (141) coinciding with an expected location of a build plane (142), an energy beam system (132) with an irradiation device (138) configured to generate an energy beam (134) and to direct the energy beam (134) upon the build plane (142), and a position measurement system (150) configured to determine a position of the build plane (142). A position measurement assembly (200) includes one or more position sensors (202), and one or more mounting brackets (204) configured to attach the one or more position sensors (202) to an energy beam system (132) of an additive manufacturing machine (100). The position measurement assembly (200) is configured to determine a position of a build plane (142) with the energy beam system (132) situated in a fixed position relative to a reference plane (141) coinciding with an expected location of the build plane (142).