SLM Build Space Scanning for Precise Hybrid Component Alignment
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Solution Overview
Problem
Existing SLM systems lack the precision to accurately determine the location and dimensions of components within the system, especially when combining sections manufactured using different processes, leading to potential misalignment and manufacturing tolerances.
Innovation Solution
A method involving scanning the upward-facing surface of the installation space with laser radiation of controlled power and duration to detect thermal radiation, allowing for accurate inference of component position and dimensions without melting the component or powder, and using this data to create a three-dimensional computer model for precise alignment and subsequent selective laser melting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If laser radiation with high power and long exposure time is used to detect the component, then the detected radiation signal is stronger, but the component and powder may be melted
Solution Approach 1:
The patent uses pulsed laser radiation with controlled duration to scan the build space. By using short pulses instead of continuous radiation, the system accumulates sufficient signal over multiple pulses without delivering enough total energy to melt the material. The pulse duration and frequency are carefully controlled to balance signal detection needs with material safety.
Solution Approach 2:
The patent optimizes multiple parameters of the laser radiation including power, exposure time, and wavelength to achieve detection without melting. By adjusting these parameters within specific ranges, the system generates sufficient thermal radiation signal for detection while keeping the total energy input below the melting threshold of the component and powder materials.
2Measurement precision
If conventional SLM systems are used without modification, then the system structure is simple, but the position and dimensions of the component cannot be determined with high accuracy
Solution Approach 1:
The patent makes the existing laser source perform dual functions: it serves both as the detection source for scanning and measuring the component, and as the processing laser for selective laser melting. This multi-functionality eliminates the need for separate detection and processing laser systems, maintaining system simplicity while enabling high-precision measurement.
Solution Approach 2:
The system uses its own laser source to perform both measurement and processing tasks. The laser radiation that would otherwise be used solely for melting is now also utilized for scanning and detecting the component's position and dimensions, allowing the system to self-measure without external measurement equipment.
3Volume of moving object
If sections are combined from different manufacturing processes, then large components can be produced, but alignment precision between sections deteriorates
Solution Approach 1:
The patent performs measurement and determination of component position and dimensions before the actual selective laser melting process. By scanning and identifying the component's exact location and geometry in advance, the system can plan and execute the melting process with precise alignment, ensuring that sections from different manufacturing processes fit together accurately.
Solution Approach 2:
The system uses the detected radiation signal to obtain feedback information about the component's position and dimensions. This feedback is used to adjust and optimize the selective laser melting process parameters and positioning, ensuring precise alignment between sections. The measured data guides the subsequent processing to achieve accurate assembly of hybrid-manufactured components.
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 high-accuracy determination of component position and dimensions, allowing for precise fitting of hybrid SLM components and reducing manufacturing tolerances, while allowing for cost-effective retrofitting of conventional SLM systems using the same laser source.
Implementation Method 1
detecting radiation which is generated due to an interaction of the laser radiation with the build space
Implementation Method 2
The interaction can, for example, also be a heating of the build space, which means that the laser radiation is at least partially absorbed by the build space and, according to the invention, thermal radiation emitted by the build space is measured in step c)
Implementation Method 3
The interaction can, for example, be a reflection and/or scattering on the upward-facing surface of the build space
Implementation Method 4
The interaction can, for example, be a reflection and/or scattering on the upward-facing surface of the build space
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a method for operating an SLM system (1), comprising the steps: a) providing a construction space (17) in the SLM system (1), which construction space comprises a component (2) and, adjacent thereto, a powder (3), a surface (18) of the construction space (17) that faces upward having regions that are formed by the component (2) and other regions that are formed by the powder (3); b) scanning the surface (18) that faces upward with laser radiation, the power and duration of action of which are selected in such a way that the component (2) and the powder (3) are not melted; c) detecting radiation that results from interaction of the laser radiation with the construction space (17); d) inferring a position and dimensions of the component (2) from the radiation detected in step c).