Building Platform Positioning With Laser Targets for Precise AM Alignment
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Solution Overview
Problem
Existing additive manufacturing devices face challenges in accurately aligning and bonding three-dimensional components built on prefabricated lower parts due to limitations in determining the precise position of the building platform within the coordinate system of the laser scanner, particularly in high-precision applications like dental manufacturing where accuracy requirements exceed +/-50 μm.
Innovation Solution
A method and system that determine the position data of a building platform on a support plate within an additive manufacturing device by obtaining precision position datasets using a vision measuring device and laser marks, combining external high-resolution images with internal camera data to achieve accurate alignment and bonding, utilizing a support plate with building platform holes and optically detectable reference marks, and receptors for laser target parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a prefabricated lower part (building platform) is used to produce hybrid three-dimensional components, then the applicability and functionality of additive manufacturing are improved, but the alignment accuracy and bonding quality between the upper and lower parts deteriorate due to inability to precisely determine the building platform position within the laser scanner coordinate system
Solution Approach 1:
The patent introduces laser target parts as intermediary elements that are attached to the building platform. These target parts serve as mediators between the building platform position and the laser scanner coordinate system, enabling precise determination of the platform's location through laser marking and image capture, thereby resolving the alignment accuracy issue while maintaining hybrid component production capability
Solution Approach 2:
The patent replaces mechanical alignment methods with an optical measurement system. Instead of relying on mechanical fixtures or manual alignment, the system uses laser marking, camera imaging, and coordinate transformation algorithms to determine the building platform position, achieving sub-50 μm alignment accuracy that mechanical systems cannot provide
2Device complexity
If the position of the building platform is determined using conventional methods, then the device complexity is reduced, but the measurement precision of the building platform position deteriorates and cannot meet high-precision requirements of +/-50 μm
Solution Approach 1:
Laser target parts are introduced as intermediary elements that facilitate precise measurement. These target parts provide distinct visual features for camera detection and serve as reference points for coordinate transformation, enabling high-precision position determination without requiring complex direct measurement systems
Solution Approach 2:
The patent creates an optical copy of the building platform position information through laser marking and camera imaging. The laser marks on the target parts create a visual representation of the platform's location, which can be captured, processed, and transformed into precise coordinate data, achieving high measurement precision through information copying rather than direct physical measurement
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 alignment and strong bonding between the upper and lower parts of three-dimensional components with an accuracy better than 50 μm, enhancing the quality of hybrid components and expanding the applicability of additive manufacturing to high-precision products like dental prosthetics.
Implementation Method 1
The laser beam melts or sinters the powder material locally to produce a three-dimensional component layer by layer
Implementation Method 2
The laser beam melts or sinters the powder material locally to produce a three-dimensional component layer by layer
Implementation Method 3
scanner optics for scanning a laser beam across a working plane over a powder bed
Implementation Method 4
acquiring a pre-manufacturing image of the support plate that has the laser marks on the laser target parts and is mounted within the process chamber
Data Source
AI summary
A method determines position data of a platform at a plate of an additive manufacturing device, having scanner optics for scanning a laser. The plate has holes that receive a holder, marks on the plate, and receptors for receiving laser target parts. A first position dataset is obtained with a position of a holder inserted in a hole with respect to the marks. After mounting the plate and inserting the platform into the holder, a laser mark is marked on the laser target parts using the laser at laser mark positions in the scanner optics' coordinate system. A pre-manufacturing image of the support plate is acquired with the laser marks on the laser target parts. A second position dataset having positions of the marks with respect to the laser marks is obtained from the pre-manufacturing image. The position data is determined from the position datasets and the laser mark positions.