Automatic Scanner Calibration for 3D Printing
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Solution Overview
Problem
Existing methods for calibrating devices that generate three-dimensional objects are limited in their ability to produce large objects dimensionally accurately and rapidly, especially when using multiple scanners, as they require manual calibration before the construction process and are not designed for real-time adjustment during object production.
Innovation Solution
A method for automatically calibrating a device with multiple scanners that allows for overlap correction of scan zones during the construction process, using test patterns to detect and correct deviations in scanner alignment and intensity, enabling simultaneous irradiation of large areas and real-time calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple scanners are used to cover enlarged construction zones, then productivity is improved by simultaneous exposure of layers at multiple locations, but manufacturing precision deteriorates due to difficulty in maintaining dimensional accuracy across multiple scan zones
Solution Approach 1:
The patent implements automatic calibration using a camera to detect test patterns produced by multiple scanners, measuring deviations from reference positions and feeding this information back to the control device, which calculates correction values to adjust scanner positions and ensure accurate overlap regions across multiple scan zones
Solution Approach 2:
The system dynamically adjusts scanner parameters (position, orientation, exposure) based on detected deviations from the calibration process, modifying operational parameters in real-time to maintain dimensional accuracy across enlarged construction zones covered by multiple scanners
2Manufacturing precision
If manual calibration is performed before construction process, then manufacturing precision can be maintained, but loss of time increases due to calibration being separate from production process
Solution Approach 1:
The system performs preliminary calibration actions by producing test patterns and detecting deviations before actual construction begins, establishing correction values in advance that are stored and applied during the construction process, thereby maintaining precision without time loss during production
Solution Approach 2:
The calibration system is self-contained and automated, using the device's own camera and control device to perform calibration without requiring external manual intervention, allowing calibration to be integrated into the production workflow rather than being a separate time-consuming step
3Area of stationary object
If scan zones are overlapped to cover large construction zones, then area of construction zone is increased, but manufacturing precision deteriorates due to difficulty in correcting overlap deviations
Solution Approach 1:
The camera detects deviations in the overlap regions between adjacent scan zones by comparing test pattern positions against reference positions, and the control device uses this feedback to calculate and apply correction values that ensure accurate alignment and seamless transitions between zones covered by different scanners
Solution Approach 2:
The construction zone is divided into multiple scan zones covered by different scanners, with each zone calibrated independently through test pattern detection, allowing precise control and correction of overlap regions between segmented zones while maintaining overall dimensional accuracy across the entire enlarged construction area
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
Enables the production of large, dimensionally accurate three-dimensional objects by automatically correcting scanner overlap and deviations during the construction process, significantly reducing production time and improving the device's ability to handle large construction zones.
Implementation Method 1
The radiation sources 10, 11 are preferably light sources such as lasers
Implementation Method 2
the beam 12 impinging on the first scanner 14 is reflected and is directed as beam 20 onto a first scan zone 30
Data Source
AI summary
A method for automatically calibrating a device for generatively producing a three-dimensional object (8) comprises the following steps: irradiating an applied layer of a material (3) or a target by means of a first scanner (14) in order to produce a first test pattern (33) in the material (3) or the target; irradiating the applied layer of the material (3) or the target by means of a second scanner (15) in order to produce a second test pattern (34) in the material (3) or the target; detecting the first and second test patterns (33, 34) by means of a camera (24) and assigning the first and second test patterns (33, 34) to the first and second scanners (14, 15), respectively; comparing the first and/or the second test pattern (33, 34) with a reference pattern and/or comparing the first and second test patterns (33, 34) with one another; determining a first deviation of the first test pattern (33) from the reference pattern and/or a second deviation of the second test pattern (34) from the reference pattern and/or a relative deviation between the first test pattern (33) and the second test pattern (34); and calibrating the first and/or the second scanner (14, 15) in such a way that the first and/or the second deviation from the reference pattern and/or the relative deviation between the first test pattern (33) and the second test pattern (34) falls below a setpoint value.