Removable Calibration Plate for Precise Additive Manufacturing Imaging
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Solution Overview
Problem
Existing calibration methods for additive manufacturing apparatuses are dependent on the calibration plate being present in the apparatus, limiting flexibility and precision in image acquisition, and suffer from radiation beam reflections and poor detection of contours and surfaces.
Innovation Solution
A removable calibration plate with an etching layer that is opaque to visible light and can be etched by a powerful radiation beam to create reference and test markings, allowing for external image capture and improved precision through backlighting, using a portable kit with an image-capture apparatus to calculate aiming-command corrections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the calibration plate is kept inside the additive manufacturing apparatus for image acquisition, then the calibration process can be performed, but the image acquisition precision is limited and the system lacks flexibility
Solution Approach 1:
The calibration plate is extracted from the additive manufacturing apparatus, allowing it to be imaged externally with higher precision equipment. The plate can be removed from the apparatus and placed on a separate imaging system, decoupling the calibration measurement process from the manufacturing process.
Solution Approach 2:
A transparent sheet with frosted lower face acts as an intermediary carrier for the etching layer. This mediator allows the calibration markings to be created by the laser apparatus but imaged externally through the transparent sheet, bridging the two systems.
2Manufacturing precision
If a powerful radiation beam is used to etch test markings on the calibration plate, then the markings can be created, but reflections from the beam reduce measurement precision
Solution Approach 1:
The harmful reflections from the laser beam are converted into a beneficial effect. The frosted lower face of the transparent sheet diffuses the reflected beam, transforming the harmful concentrated reflection into a beneficial diffuse transmission that allows external imaging through the sheet while preventing harmful reflections.
Solution Approach 2:
Different regions of the calibration plate have different optical properties. The upper face is transparent for marking creation, the etching layer provides selective opacity for marking formation, and the lower face is frosted to diffuse reflections. Each region is optimized for its specific function.
3Manufacturing precision
If the etching layer is made opaque to visible light, then test markings can be formed by laser etching, but the markings cannot be viewed from the backside
Solution Approach 1:
Instead of viewing the markings from the same side they are created (topside viewing), the system inverts the viewing approach by using a transparent sheet that allows backlighting from below. The markings are formed in an opaque etching layer, but the transparent sheet enables viewing through the backside with improved contrast.
Solution Approach 2:
The optical properties of the materials are optimized for specific wavelengths. The etching layer is opaque to visible light for marking formation, but the transparent sheet allows visible light transmission for imaging, creating a contrast that enhances marking visibility when backlit.
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
Enhances precision in detecting contours and surfaces by overcoming radiation reflections and enabling external image acquisition, improving the accuracy of calibration without requiring the calibration plate to be in the apparatus.
Implementation Method 1
the at least one etching layer to be etched by a powerful incident-radiation beam being able to be destroyed locally by the powerful incident-radiation beam in order to form the at least one test marking
Implementation Method 2
The frosted lower face of the sheet overcomes the disadvantage of reflections of the beam of radiation off this lower face during the etching of the test markings by this beam of radiation on the calibration plate
Implementation Method 3
the sheet being transparent to visible light, the lower face of the sheet being frosted
Data Source
AI summary
A removable calibration plate (10) comprises a sheet (20) comprising an upper face (21) intended to face towards the powerful incident-radiation beam, and bearing a reference marking (30) and being intended to receive a test marking (40), and a lower face (23). The plate (10) comprises an etching layer (22) to be etched by a powerful incident-radiation beam (F), this layer being secured to the upper face (21) of the sheet (20) and opaque to visible light, and being able to be destroyed locally by the powerful incident-radiation beam (F) in order to form the at least one test marking (40), the sheet (20) being transparent to visible light, the lower face (23) of the sheet (20) being frosted.