In-Process Dimensional Inspection for Powder Bed Components
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Solution Overview
Problem
Existing additive manufacturing technologies face challenges in inspecting the quality and integrity of components during the manufacturing process due to the compactness of the machines, toxic atmosphere, and fragility of equipment, making it difficult to evaluate compliance and quality of complex internal geometries without impairing the manufacturing process.
Innovation Solution
A method for dimensionally inspecting components using a CMOS or CCD camera to acquire images during the manufacturing process, comparing them with a reference template to check compliance, and modifying the process if non-compliance is detected, allowing for early intervention and reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the additive manufacturing machine is made compact and the booth is hermetically sealed to ensure manufacturing quality and safety, then manufacturing quality and safety are improved, but access for inspection is restricted and equipment fragility increases
Solution Approach 1:
The patent replaces mechanical inspection methods (requiring physical access to the booth) with optical inspection using a camera system. The camera captures images of the component through the transparent or translucent window of the sealed booth, eliminating the need to open the hermetic seal or disassemble the compact machine structure for inspection purposes.
Solution Approach 2:
The patent introduces a camera system as an intermediary between the inspector and the component. The camera acts as a mediator that can penetrate through the sealed booth environment and capture images of the component's internal geometries, allowing inspection without direct physical access to the restricted manufacturing environment.
2Measurement precision
If conventional non-destructive inspection methods are used after manufacturing, then inspection capability is provided, but the component cannot be inspected during the manufacturing process and material waste increases
Solution Approach 1:
The patent implements preliminary inspection by capturing images of the component during the additive manufacturing process itself, rather than waiting until manufacturing is complete. The camera system continuously or periodically captures images at various stages of construction, enabling early detection of dimensional non-compliance before the component is fully manufactured and thus preventing material waste.
3Object-affected harmful factors
If the booth atmosphere is hermetically sealed to prevent toxic gas and powder inhalation, then safety is improved, but inspection access is completely blocked
Solution Approach 1:
The patent substitutes mechanical inspection access with optical imaging through the booth window. The camera system captures images of the component's internal structures through the transparent or translucent window of the sealed booth, enabling inspection without breaking the hermetic seal or exposing the inspector to toxic atmosphere.
Solution Approach 2:
The camera system serves as an intermediary that bridges the isolation created by the hermetic seal. It allows visual inspection of the component through the sealed booth environment, maintaining the protective barrier while still enabling measurement and detection of dimensional compliance.
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 real-time inspection of component compliance, reducing material loss and production time by stopping non-compliant components early and optimizing the manufacturing process.
Implementation Method 1
Acquiring an image of the component being manufactured
Data Source
AI summary
A method for dimensionally inspecting at least one component manufactured by an additive manufacturing machine, the additive manufacturing being carried out by successive depositions of a powder bed and by fusing the powder bed after each deposition, the method including acquiring an image of the component being manufactured after at least one procedure of depositing and fusing the powder bed; comparing the image with an image of a reference template; verifying the dimensional conformity of the component on the basis of the comparison.