Optical Fiber Beam Calibration for Additive Manufacturing Alignment
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Solution Overview
Problem
Existing additive manufacturing machines face challenges in accurately calibrating their energy beam systems, which affects the alignment and material properties of additively manufactured three-dimensional objects, leading to inconsistencies in the manufacturing process.
Innovation Solution
The implementation of a calibration system that uses a calibration beam emitted through an optical fiber, reflected off a substrate, and detected by a fiber end, allowing for alignment adjustments based on signal intensity and position, ensuring precise alignment with the optical axis, thereby improving the energy beam system's alignment and material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional calibration methods are used for energy beam systems, then the calibration process is simple, but the alignment precision and material properties of manufactured objects deteriorate
Solution Approach 1:
A calibration substrate with reflective surface is introduced as an intermediary element between the energy beam system and the detection device. This substrate enables precise measurement of beam alignment by reflecting the calibration beam back through the optical path, allowing detection of deviations without directly measuring the beam position at the target location.
Solution Approach 2:
The system implements feedback by detecting the reflected calibration beam and using this information to determine alignment accuracy. The detection device measures the position and intensity of the reflected beam, providing feedback signals that indicate whether the energy beam system is properly aligned with the optical axis, enabling iterative correction of alignment errors.
2Manufacturing precision
If calibration operations are performed frequently to maintain alignment, then manufacturing consistency improves, but production time increases
Solution Approach 1:
The calibration substrate is pre-positioned at a known location within the build chamber before manufacturing operations begin. The calibration beam path is pre-configured through the optical fiber and scanning mirrors to intersect with the substrate's reflective surface at the correct angle, so that alignment verification can be performed quickly without requiring complex setup procedures each time calibration is needed.
Solution Approach 2:
The patent replaces mechanical alignment adjustment mechanisms with an optical-based calibration system. Instead of physically adjusting mirrors and lenses during calibration, the system uses optical fiber transmission and reflective surface detection to determine alignment status, reducing the time and complexity of calibration operations while maintaining precision.
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 enhances the alignment of the energy beam system, resulting in improved material properties and consistency of additively manufactured objects by accurately calibrating the additive manufacturing machine's energy beam system.
Implementation Method 1
A calibration beam is emitted from an optical fiber
Implementation Method 2
the reflected beam including a portion of the calibration beam having been reflected by the reflective surface
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A method (500) of calibrating an additive manufacturing machine (102) includes detecting a reflected beam (218) becoming incident upon a detection device (206), the reflected beam (218) comprising a portion of a calibration beam (208) having been reflected by a reflective surface (216) of a calibration substrate (214); and determining an alignment of the reflected beam (218) and/or the calibration beam (208) with an optical axis (300) based at least in part on detecting the reflected beam (218) becoming incident upon the detection device (206); wherein, the reflected beam (218) becomes incident upon a fiber end (207) of an optical fiber (204) and propagates through the optical fiber (204) prior to becoming incident upon the detection device (206), the optical fiber (204) defining a portion of a detection path (222) from the reflective surface (216) to the detection device (206).