Optical Thermal Energy Mapping for Additive Manufacturing Control
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Solution Overview
Problem
Current additive manufacturing processes lack effective non-destructive methods for verifying the mechanical, geometrical, and metallurgical properties of production parts, as conventional quality assurance testing often requires destructive testing, which is not applicable to production parts.
Innovation Solution
The implementation of optical sensing techniques to track in-process physical phenomena and calculate thermal energy density (TED) during additive manufacturing, using sensors that monitor energy radiated from the build plane, allowing for real-time adjustment of process parameters to prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional quality assurance testing is used to verify part properties, then measurement accuracy is improved, but the part is destroyed
Solution Approach 1:
The patent replaces mechanical contact-based measurement systems with optical sensing systems. Optical sensors detect thermal radiation and electromagnetic signals from the melt pool without physical contact, enabling quality monitoring while preserving part integrity. This substitution of measurement methodology resolves the contradiction between obtaining accurate quality data and maintaining part usability.
2Loss of information
If optical sensors are used to monitor thermal energy, then measurement capability is improved, but device complexity increases
Solution Approach 1:
The optical sensing system is designed to perform multiple functions: monitoring thermal energy density, tracking melt pool characteristics, detecting process anomalies, and providing real-time feedback for control. By consolidating these functions into a single multi-functional sensing system, the patent minimizes the increase in device complexity while maximizing information availability about the additive manufacturing process.
3Manufacturing precision
If real-time process monitoring is implemented, then manufacturing precision is improved, but processing time increases
Solution Approach 1:
The patent implements real-time feedback control where optical sensors continuously monitor thermal energy density and melt pool characteristics, and the system automatically adjusts process parameters based on this feedback. This closed-loop control improves manufacturing precision by maintaining optimal melt pool conditions while the real-time nature of the feedback ensures minimal delay in detection and correction, thus limiting the time penalty.
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
Enables non-destructive quality inference and process control, reducing discontinuities in the melt pool size and temperature variations, thereby improving the accuracy and consistency of additive manufacturing processes.
Implementation Method 1
measuring an amount of energy radiated from the build plane during each of the plurality of scans using an optical sensor monitoring the build plane
Data Source
AI summary
This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensor; determining an area of the build plane traversed during the scans; determining a thermal energy density for the area of the build plane traversed by the scans based upon the amount of energy radiated and the area of the build plane traversed by the scans; mapping the thermal energy density to one or more location of the build plane; determining that the thermal energy density is characterized by a density outside a range of density values; and thereafter, adjusting subsequent scans of the energy source across or proximate the one or more locations of the build plane.