Single-Scan Mill Calibration Using 3D Milled Reference Blocks

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Solution Overview

Problem

CNC milling machines experience misalignment due to vibrations and resistive forces, leading to defects in precision objects like dental prostheses, and manual calibration is time-consuming and challenging.

Innovation Solution

An automated method involving a 3D virtual calibration design is milled into a physical block, scanned, and parameters are determined to calibrate the milling machine, using a computer-implemented system with a 3D scanner and cloud computing for alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual alignment is performed, then the milling machine can be calibrated, but the process is time-consuming and labor-intensive

Engineering Contradiction:

Improvecalibration accuracyVSAvoidcalibration time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical measurement operations with an automated optical scanning system. A 3D scanner captures the calibration block geometry, and software automatically compares scanned features against CAD models to determine calibration parameters, eliminating manual micrometer measurements and data recording while maintaining measurement precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The calibration system performs self-measurement by using the milling machine itself to mill the calibration block, then using a scanner to capture the block's geometry. The system automatically processes the scan data against the original CAD design to generate calibration parameters without requiring external measurement tools or manual intervention.

Inventive Principle:

Principle #25Self-service

2Productivity

If repeated milling operations are performed, then production output increases, but vibrations and resistive forces cause misalignment and defects

Engineering Contradiction:

Improvemilling outputVSAvoidalignment accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent performs calibration before production milling operations by milling a calibration block, scanning it, and determining calibration parameters that compensate for potential misalignment. This preliminary calibration establishes accurate machine parameters that prevent defects during subsequent production milling, allowing repeated operations without accumulating alignment errors.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses 3D scanning to capture the actual geometry of the calibration block after milling, compares it against the original CAD design, and automatically generates calibration parameters based on the measured deviations. This feedback loop identifies and corrects misalignment caused by vibrations and resistive forces, maintaining precision across repeated milling operations.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS20260001184A1Mill calibration with single scan

Publication Date: 2026.01.01 JAMES R GLIDEWELL DENTAL CERAMICS

AI summary

A computer-implemented system, method, and medium of automated milling machine calibration includes receiving a 3D virtual calibration design comprising one or more designed indented regions and a designed curved region; milling the 3D virtual calibration design into a physical block to provide a 3D physical milled calibration block; receiving a 3D virtual calibration scan block of the 3D physical milled calibration block; and determining one or more calibration parameters from the 3D virtual calibration scan block.