3D Printer Optical Monitoring for Layer Defect Detection
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Solution Overview
Problem
Current 3D printing processes face challenges in monitoring the quality of material application during the printing process, leading to potential defects such as incorrect placement, bubbles, and gaps, which are often detected only after completion through costly and time-consuming non-destructive testing methods.
Innovation Solution
A method and device utilizing a stationary camera with an optical deflection device to monitor the material application in real-time, allowing for continuous recording of the material's geometry and position relative to the target specification, enabling immediate detection of defects and potential abortion of the manufacturing process if necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If material is applied layer by layer by print head, then component is manufactured, but defects such as incorrect placement, bubbles, and gaps occur that are detected only after completion
Solution Approach 1:
The patent applies preliminary action by implementing real-time optical monitoring during the printing process itself, rather than waiting for completion to detect defects. The camera system continuously captures images of the material application process, allowing defects to be identified and addressed immediately while the component is still being manufactured.
Solution Approach 2:
The patent implements feedback by using the captured images to immediately detect and report defects in material application. The system provides real-time feedback about the quality of material deposition, enabling corrective actions to be taken during the printing process rather than after completion.
2Reliability
If non-destructive testing methods such as X-ray or ultrasonic testing are used after completion, then defects can be detected, but costs and time are doubled
Solution Approach 1:
The patent performs defect detection in advance during the printing process itself, eliminating the need for separate post-production testing. By capturing images during material application, the system identifies defects before the component is completed, saving time and resources that would otherwise be spent on X-ray or ultrasonic testing.
Solution Approach 2:
The patent uses optical copying through camera imaging to create a visual record of the material application process. This optical copy allows for defect detection without requiring physical intervention or complex testing equipment, providing a simpler and faster alternative to X-ray or ultrasonic testing.
3Measurement precision
If camera is mounted on print head for direct detection, then real-time monitoring is possible, but camera is exposed to high temperatures and moving parts
Solution Approach 1:
The patent uses an intermediary approach by mounting the camera on the print bed rather than directly on the print head. This intermediary positioning allows the camera to capture images of the material application process from a safe distance, avoiding direct exposure to high temperatures and moving parts while still enabling real-time monitoring.
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 solution allows for real-time monitoring of material application quality, preventing defective components and eliminating the need for complex post-production testing, thereby reducing costs and time associated with correcting errors.
Implementation Method 1
the deposit is detected by the at least one camera by means of at least one optical deflection device
Data Source
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Figure 5~7
AI summary
The invention relates to a method for the optical monitoring of a component (6) manufactured by a 3D printing process, wherein, in the 3D printing process, a material is deposited layer by layer as a build-up (7) onto the component (6) under construction by means of at least one print head (2). The invention further relates to a 3D printer (1) for manufacturing a component (6), wherein the component (6) can be manufactured by depositing a material layer by layer as a build-up (7) by means of a print head (2). The invention is therefore based on the objective of providing a method and a device with which the quality of the build-up (7) and thus the quality of the component (6) to be manufactured can be monitored during the 3D printing process. This objective is achieved by optically capturing the build-up (7) by means of at least one camera (8) and comparing it with a geometric target specification.The device according to the invention is a 3D printer (1) which includes at least one camera (8) for optical monitoring of the job (7).