Additive Manufacturing Scanner Calibration Without Opening the Build Chamber
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Solution Overview
Problem
Current calibration methods for laser beam power and scanner accuracy in additive manufacturing require opening the build chamber, making them time-consuming and only possible sporadically, preventing interim calibration during product manufacturing.
Innovation Solution
An apparatus and method allowing the scanning means to move between a production position and a calibration position within the build chamber, enabling calibration of the laser beam power and scanner accuracy without opening the chamber, using guiding means and a calibration device outside the chamber to measure and adjust parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If calibration is performed using existing methods (sensors in build chamber or coordinate measurement machines), then measurement precision is improved, but productivity deteriorates because the process chamber must be opened and calibration can only be done sporadically
Solution Approach 1:
The calibration device is extracted from the build chamber and placed in an external calibration position. The scanning means are movable between the production position (inside build chamber) and calibration position (outside build chamber). This allows calibration measurements to be performed externally without opening the process chamber, eliminating the need to interrupt production for calibration.
Solution Approach 2:
The scanning means are made dynamically movable between two positions: production position for manufacturing and calibration position for measurements. This dynamic repositioning capability enables the system to switch between manufacturing and calibration modes without opening the chamber, maintaining production continuity while enabling regular calibration.
2Manufacturing precision
If calibration is performed by building a product and measuring its dimensions with coordinate measurement machines, then manufacturing precision can be verified, but loss of time increases due to the lengthy process of building and measuring
Solution Approach 1:
Instead of waiting until a product is built to verify precision, the system performs preliminary calibration actions by positioning the scanning means at the calibration position where reference measurements are taken against known calibration standards. This allows calibration to be performed quickly without building actual products, reducing time loss while maintaining manufacturing precision verification.
Solution Approach 2:
The calibration device uses reference objects or calibration standards with known dimensions placed at the calibration position, creating a reference copy of the measurement system's performance. This allows verification of manufacturing precision through reference measurements rather than building and measuring actual products, significantly reducing calibration time.
3Measurement precision
If sensors are placed in the build chamber to measure laser beam power and scanner position, then measurement precision is improved, but device complexity increases and the chamber must be opened for sensor installation and maintenance
Solution Approach 1:
The calibration device and measurement sensors are extracted from the build chamber and relocated to an external calibration position. The scanning means move to this external position for calibration measurements. This simplifies the system by eliminating the need for sensors inside the chamber, reducing device complexity while maintaining measurement precision through external reference measurements.
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 fast and simple calibration of the laser beam power and scanner accuracy during ongoing product manufacturing, maintaining production pressure and atmosphere, allowing for regular calibration without interrupting the process.
Implementation Method 1
a beam source (9) to generate an energy beam (6), with corresponding scanning means (10) to move a point of incidence of the beam (6)
Implementation Method 2
a calibration device (3) for said beam source (9) and/or said scanning means (10)
Data Source
AI summary
An apparatus for layered manufacture of a three-dimensional product includes a build chamber having a window, a build platform within the build chamber, a calibration device that is physically separated from the build chamber, an optical system including a beam source and a scanning apparatus, and a mobile base. The mobile base is configured to position the scanning apparatus at two spaced part positions including a (1) production position and a (2) calibration position. At the production position the scanning apparatus is configured to receive an energy beam from the beam source and to reflect and scan the energy beam through the window and to a build surface over the build platform to create a layer of the three-dimensional product. At the calibration position the scanning apparatus is configured to reflect the energy beam to the calibration device but not through the window.