Sensor Fusion for Additive Manufacturing Defect Detection
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Solution Overview
Problem
In additive manufacturing, monitoring and detecting defects within sealed chambers with limited space and obstructed visual access is challenging, making it difficult to predict potential failure modes in parts being formed.
Innovation Solution
A system with multiple sensors collects physical property data from each layer during manufacturing, aggregating and comparing this data to generate a model that identifies potential failure modes, allowing for real-time defect detection and adjustment of manufacturing parameters to prevent failure propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sealed chamber is used to control atmosphere during additive manufacturing, then oxidation in powder beds is reduced, but monitoring and detection of defects becomes difficult due to limited space and obstructed visual access
Solution Approach 1:
The patent introduces sensors as intermediary devices that can detect physical properties (temperature, acoustic emissions, vibrations) of the part and powder bed through the sealed chamber walls or via limited access points, enabling defect detection without compromising the sealed atmosphere control
Solution Approach 2:
The patent replaces direct visual inspection (mechanical/optical system) with sensor-based detection systems that measure physical properties such as acoustic emissions, vibrations, and temperature, allowing defect detection through the sealed chamber barrier
2Manufacturing precision
If powder beds are used to create layers in additive manufacturing, then fine geometric features can be produced, but the part is substantially covered by powder throughout the manufacturing process, obstructing visual inspection
Solution Approach 1:
The patent uses sensors positioned to detect physical properties of the part through or around the powder bed, serving as intermediaries that can 'see' defects without requiring direct visual access to the powder-covered part
Solution Approach 2:
The patent substitutes visual inspection with sensor-based detection of acoustic emissions, vibrations, and thermal properties, enabling defect detection without removing or disturbing the powder bed that provides manufacturing precision
3Volume of stationary object
If limited space is available within the sealed chamber for sensors, then the chamber design is compact, but sensor placement and data collection for comprehensive monitoring becomes challenging
Solution Approach 1:
The patent employs sensors that serve multiple functions - detecting temperature, acoustic emissions, and vibrations simultaneously - reducing the number of separate devices needed within the limited chamber space while maintaining comprehensive monitoring capability
Solution Approach 2:
The patent combines multiple sensing capabilities into integrated sensor systems or positions multiple sensors to monitor multiple parameters simultaneously, optimizing the use of limited space within the sealed chamber
Data Source
Figure 1a~1c
Figure 2
Figure 3
AI summary
A system (10) for additive manufacturing a component (12) includes an additive manufacturing machine (14) for building a component layer by layer (18, 20, 21), first and second sensors (34, 36) configured to collect first and second physical property data for each layer (18, 20, 21) of the component (12) as each layer (18, 20, 21) is formed by the additive manufacturing machine (14). A computing device (40) is operatively connected to the first and second sensors (34, 36) and configured to receive the first and second physical property data of the component (12) and configured to compare the first physical property data with the second physical property data to determine a potential failure mode in the component (12).