Smart Build Platform Sensing for Real-Time Additive Quality Monitoring
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Solution Overview
Problem
Additive manufacturing processes face challenges in obtaining real-time feedback and data on the quality of parts being fabricated, leading to potential hidden flaws and resource wastage due to excessive residual stresses.
Innovation Solution
Integration of sensors within the additive manufacturing build platform, such as fiber optic sensors, thermocouples, and strain gauges, to gather data on the manufacturing process and parts, connected to a computer processor for real-time analysis, using ultrasonic additive manufacturing to deposit metal layers and create a 'smart baseplate' for monitoring temperature, strain, and other conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are integrated into the additive manufacturing build platform, then real-time quality monitoring capability is improved, but device complexity increases
Solution Approach 1:
The patent merges the sensor system with the additive manufacturing build platform by integrating sensors directly into the build platform structure. This combining approach allows real-time quality monitoring while reducing overall system complexity compared to using separate external monitoring systems.
Solution Approach 2:
The build platform is designed to serve multiple functions: it acts as both the structural foundation for additive manufacturing and as an integrated sensing system. This multi-functionality improves measurement precision while avoiding the need for additional separate devices, thereby managing device complexity.
2Manufacturing precision
If real-time feedback systems are implemented, then manufacturing precision is improved, but loss of time during setup and data processing increases
Solution Approach 1:
The sensors are pre-integrated into the build platform before the additive manufacturing process begins. This preliminary integration eliminates setup time during production and enables immediate real-time monitoring from the start of manufacturing, improving precision without significant time loss.
Solution Approach 2:
The system implements real-time feedback by continuously collecting data from sensors during the additive manufacturing process and providing immediate information about part quality and process conditions. This enables及时调整 (adjustment) during manufacturing to maintain high precision while minimizing post-processing time.
3Reliability
If multiple sensors are embedded in the build platform, then reliability of quality monitoring is improved, but ease of manufacture deteriorates
Solution Approach 1:
The sensor system is segmented into multiple independent sensors distributed across the build platform. Each sensor monitors specific parameters, and their combined data provides comprehensive and reliable quality monitoring. The segmented approach allows for targeted placement of sensors in critical areas without requiring complete redesign of the entire build platform.
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 real-time quality monitoring, reduces production overhead, enhances repeatability, and facilitates a flexible supply chain by providing standardized process control technology, allowing for early detection of potential part failures and improved part qualification.
Implementation Method 1
strain gauges, to gather data on the manufacturing process and parts
Implementation Method 2
thermocouples, and strain gauges, to gather data on the manufacturing process and parts
Implementation Method 3
using ultrasonic additive manufacturing to deposit metal layers and create a 'smart baseplate' for monitoring
Data Source
AI summary
A method for quality control monitoring of additive manufacturing processes comprising forming at least one channel in an additive manufacturing build platform, wherein the channel is formed in the upper surface of the build platform to a predetermined depth, and wherein the channel is formed in a predetermined pattern across the upper surface of the build platform; placing a sensor in the channel formed in the upper surface of the build platform, wherein the sensor gathers information relevant to an additive manufacturing process occurring on or in close proximity to the build platform; enclosing the sensor within the channel formed in the upper surface of the build platform with an additive manufacturing substrate, wherein components or parts are built directly on the substrate using an additive manufacturing process, and using the sensor to gather information about the components or parts and the additive manufacturing process itself.