QMM3D Beam Calibration for Cross-Stitching Error Control
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Solution Overview
Problem
Current additively manufacturing apparatuses face challenges in calibrating multiple energy beams across a beam guiding plane, leading to cross stitching errors due to misalignment, which are time-consuming and cumbersome, and do not account for influences during the manufacturing process, such as thermal drift.
Innovation Solution
Incorporating a calibration unit with sub-regions of differing optical properties within the beam guiding plane, where energy beams generate calibration signals that a determination device uses to assess and align the beam guiding units, allowing for real-time calibration and minimizing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple energy beams are used to irradiate the build material, then the manufacturing speed is improved, but cross stitching errors occur due to misalignment between beam guiding units
Solution Approach 1:
The calibration unit utilizes sub-regions with different optical properties (analogous to color changes) that generate distinct calibration signals when irradiated by different energy beams. This allows the determination device to detect and correct misalignment between beam guiding units, ensuring precise stitching boundaries while maintaining high manufacturing speed with multiple beams.
2Measurement precision
If a traditional calibration process is performed outside the apparatus, then the beam guiding units can be calibrated, but the process is time-consuming and does not account for thermal drift during manufacturing
Solution Approach 1:
The calibration unit is pre-integrated into the beam guiding plane within the apparatus, allowing calibration to be performed before manufacturing begins. The calibration signals are generated in advance and stored, enabling quick reference during manufacturing without requiring time-consuming external calibration processes.
Solution Approach 2:
The calibration capability is continuously available within the apparatus during manufacturing operations. The determination device can perform real-time alignment verification and correction without interrupting the manufacturing process, ensuring continuous operation while maintaining precision despite thermal drift.
3Measurement precision
If a coordinate measurement machine is used to evaluate calibration patterns, then the calibration can be performed, but the process requires removing the test specimen and evaluating it outside the apparatus
Solution Approach 1:
The calibration unit serves as an intermediary element within the beam guiding plane that generates detectable calibration signals directly during the additive manufacturing process. This eliminates the need for external coordinate measurement machines and separate test specimen evaluation, as the calibration function is integrated into the manufacturing apparatus itself.
Solution Approach 2:
The apparatus performs its own calibration function through the calibration unit and determination device, eliminating the need for external calibration equipment and processes. The system self-verifies and self-corrects alignment between beam guiding units using the generated calibration signals, reducing device complexity and streamlining the calibration process.
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 efficient and accurate calibration of energy beams during the additive manufacturing process, reducing errors and improving the alignment of beam guiding units, thus enhancing the quality and speed of the manufacturing process.
Implementation Method 1
each layer of build material is usually irradiated with more than one energy beam
Implementation Method 2
at least one calibration region comprising a plurality of sub-regions differing in respect of at least one optical property
Data Source
AI summary
An apparatus for additively manufacturing three-dimensional objects may include at least one calibration unit, at least one irradiation device, and a determination device. The least one calibration unit may include at least one calibration region arranged in the beam guiding plane, and the at least one calibration region may include a plurality of sub-regions differing in respect of at least one optical property. The at least one irradiation device may be configured to guide a plurality of energy beams across the at least one calibration region comprising the plurality of sub-regions, and a plurality of calibration signals may be generated by the plurality of sub-regions being irradiated with the plurality of energy beams. The determination device may be configured to determine the plurality of calibration signals and to determine a calibration status of the irradiation device based at least in part on the determined plurality of calibration signals.