Recoater Blade Imaging for Powder Bed Defect Detection

The patent replaces complex mechanical inspection systems with an optical monitoring camera system. Instead of using mechanical sensors or physical inspection mechanisms to detect powder bed defects, the system uses a camera to capture images of the powder spreading process, which are then analyzed by a controller to detect defects such as sink holes and short feeds.

The patent introduces an intermediary digital image processing system between the physical powder spreading process and the defect detection function. The monitoring camera captures visual information, which serves as an intermediary data form, and the controller processes this image data to identify defects, separating the detection function from the manufacturing process.

The patent implements continuous monitoring of the powder spreading process throughout the entire manufacturing cycle. The monitoring camera operates continuously to capture images at multiple stages of powder deposition, ensuring that defects are detected in real-time without interrupting the manufacturing process, thereby maintaining continuous productive action.

The system performs preliminary detection of defects during the powder spreading process itself, before the laser melting process begins. By identifying sink holes and short feeds in advance, the system can correct these defects before they lead to component failure, preventing wasted time in later stages of detection and rework.