3D Printer Integrated Optical Cross-Section Measurement
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Solution Overview
Problem
Existing 3D printing technologies require large and expensive equipment, such as X-ray CT scanners and MRI machines, for accurate cross-section measurement of formed objects, which poses safety concerns and is inefficient.
Innovation Solution
An object-forming machine with an integrated image-capturing unit, such as CMOS or CCD, captures images of the object during formation, allowing for real-time cross-section measurement and shape determination, enabling immediate correction and reducing the need for large equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If X-ray CT scanner or MRI is used to measure cross section, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses optical imaging (camera capture) to create a visual copy of the object's cross-section during formation, replacing the need for physical X-ray CT or MRI scanning. The captured images serve as digital replicas that can be analyzed to determine cross-sectional shapes and dimensions, achieving measurement precision without requiring complex medical imaging equipment.
Solution Approach 2:
The patent replaces complex mechanical and electromagnetic systems (X-ray tubes, MRI magnets) with a simple optical system consisting of a light source and camera. This substitution uses light reflection and image capture instead of ionizing radiation or magnetic resonance, dramatically reducing device complexity while maintaining measurement capability.
2Measurement precision
If X-ray CT scanner or MRI is used to measure cross section, then measurement precision is improved, but safety concerns arise
Solution Approach 1:
The patent converts the potentially harmful X-ray and MRI procedures into a safe optical measurement process. By using reflected light captured by a camera, the system eliminates ionizing radiation exposure while maintaining the ability to measure cross-sectional geometry accurately. The harmful radiation is replaced with harmless visible light.
3Measurement precision
If dedicated large-sized measurement device is used, then measurement precision is improved, but productivity decreases
Solution Approach 1:
The patent merges the object formation process with the measurement process by capturing images during the layer-by-layer construction of the object. The imaging system operates concurrently with the manufacturing process, eliminating the need for separate post-processing measurement steps and thereby improving productivity while maintaining measurement precision.
Solution Approach 2:
The patent performs measurement actions preliminarily during the object formation process itself, rather than after completion. By capturing cross-sectional images as each layer is deposited, the system obtains measurement data in advance, enabling real-time monitoring and eliminating time-consuming post-processing scanning operations.
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 allows for accurate, safe, and efficient measurement of cross-sections during the 3D printing process, reducing material waste and production costs by enabling immediate abort or correction of the printing process based on dimensional tolerance.
Implementation Method 1
an image-capturing unit configured to capture an image of the object formed by the object-forming unit
Data Source
AI summary
A cross-section measurement method measures a cross section of a three-dimensional object formed by an object-forming machine that laminates an object material at an object-forming point. The object-forming machine includes: a table; an object-forming head; a beam supporting the object-forming head; a driver that moves the object-forming head relative to the table along the beam; an object-former on the object-forming head that laminates the object material on the table to form the object; and an imager on the object-forming head and that captures an image of the object. The object-former and the imager are indirectly supported by the beam via the object-forming head. The method includes: controlling the driver and the object-former to form the object on the table; capturing an image of the object with the imager while the object is being formed; and measuring a cross section of the object based on the captured image.