Irradiation Plane Sensor Calibration for 3D Printing Beam Accuracy
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Solution Overview
Problem
Current calibration methods for irradiation systems in powder bed fusion processes are inaccurate and unreliable, relying on burn-off foils and additional caustic measurements, which are costly and prone to errors.
Innovation Solution
A device and method utilizing a control unit and sensor arrangement to irradiate a calibration pattern onto an irradiation plane, generating a digital image of the actual pattern and comparing it to a reference, allowing for precise calibration of the irradiation system without burn-off foils and additional measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If burn-off foils and additional caustic measurements are used for calibration, then calibration can be performed, but accuracy and reliability are too low and costs increase
Solution Approach 1:
The patent uses a digital reference image (a copy of the expected irradiation pattern) to compare against the actual burn-off pattern on the foil. This digital copying and comparison method enables precise measurement of deviations without requiring physical measurement tools, thereby improving calibration accuracy and reliability while reducing costs
Solution Approach 2:
The patent replaces physical caustic measurements and manual inspection methods with a digital image processing system. The sensor arrangement captures the burn-off pattern, converts it to digital data, and automatically compares it with the reference image, substituting mechanical measurement systems with optical-digital systems to achieve higher precision and reliability
2Measurement precision
If burn-off foils and additional measurements are used for calibration, then calibration can be performed, but time and costs increase
Solution Approach 1:
The calibration process is integrated into the normal operation workflow. The sensor arrangement continuously monitors the burn-off pattern during regular irradiation operations, and the control unit performs real-time comparison with the reference image. This continuous calibration approach eliminates the need for separate, time-consuming calibration procedures while maintaining high accuracy
Solution Approach 2:
By using digital images and automated comparison algorithms, the patent eliminates time-consuming manual measurement and analysis steps. The digital reference image allows for instant, automated deviation detection, significantly reducing calibration time while maintaining or improving accuracy compared to traditional methods
3Measurement precision
If burn-off foils are used for calibration, then calibration can be performed, but the process becomes complex and costly
Solution Approach 1:
The sensor arrangement serves multiple functions: it monitors the burn-off pattern during calibration, captures images for digital analysis, and provides data for automatic comparison with the reference image. This multi-functional component simplifies the overall calibration system by consolidating multiple specialized devices into a single versatile unit, reducing complexity while maintaining measurement precision
Solution Approach 2:
The patent replaces complex mechanical measurement instruments and manual analysis procedures with a streamlined optical-sensor-digital-processing system. The control unit automatically performs image processing and deviation calculation, eliminating the need for complex manual measurement tools and reducing both device complexity and operational complexity while achieving high calibration accuracy
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
This approach enables accurate and reliable calibration of the irradiation system, reducing costs and time, and eliminating the need for burn-off foils, while ensuring high precision in focusing and beam compensation.
Implementation Method 1
a raw material powder layer is applied onto a carrier and subjected to laser radiation in a site selective manner... The laser radiation penetrating into the powder layer causes heating and consequently melting or sintering of the raw material powder particles
Implementation Method 2
A sensor arrangement which is arranged in the irradiation plane and outputs signals in response to being irradiated with the radiation beam according to the calibration pattern
Data Source
AI summary
A device for calibrating an irradiation system of an apparatus for producing a three-dimensional work piece includes a control unit to control the irradiation system so as to irradiate a radiation beam onto an irradiation plane according to a calibration pattern. The device also includes a sensor arrangement arranged in the irradiation plane to output signals to the control unit in response to being irradiated with the radiation beam according to the calibration pattern. The control unit generates a digital image of an actual irradiation pattern produced by the radiation beam incident on the sensor arrangement based on the signals output by the sensor arrangement, compares the digital image of the actual irradiation pattern with a digital image of a reference pattern so as to determine a deviation between the actual irradiation pattern and the reference pattern, and calibrates the irradiation system based on the determined deviation between the actual irradiation pattern and the reference pattern.