Imaging Parameter Adjustment Using Spot Size in Additive Manufacturing

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Solution Overview

Problem

Existing imaging devices in additive manufacturing face challenges in adjusting operational parameters, particularly focal position, due to rapidly changing intensity distributions in the build plane, which falsify results from typical autofocusing methods like contrast-based or edge detection methods.

Innovation Solution

A method to determine spot parameters related to the extension of a spot in a determination plane, calculate differences with nominal parameters, and adjust imaging device parameters accordingly, allowing for precise adjustment of focal position and other imaging parameters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If typical autofocusing methods (contrast-based or edge detection) are used to adjust imaging device parameters, then the adjustment process is simple and fast, but the rapidly changing intensity distribution in the build plane falsifies the results and reduces measurement precision

Engineering Contradiction:

Improveadjustment process simplicityVSAvoidfocal position determination accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent changes the parameter used for autofocusing from intensity distribution characteristics (contrast, edges) to spot size measurements. By determining the spot size in the determination plane and comparing it to a reference spot size, the method achieves accurate focal position determination despite rapidly changing intensity distributions in the build plane

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces a determination plane as an intermediary between the build plane and the imaging device detector. This determination plane captures the spot size information without being affected by the rapidly changing intensity distributions in the build plane, thereby providing reliable autofocusing data

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If imaging devices continuously monitor the build plane under high dynamic conditions, then process monitoring capability is maintained, but the rapidly changing properties cause flickering and falsify measurement results

Engineering Contradiction:

Improveprocess monitoring capabilityVSAvoidmeasurement result validity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent extracts the spot size information from the overall intensity distribution in the determination plane. By focusing measurement on the spot size parameter rather than the complete intensity distribution, the method isolates the reliable focal position information from the noisy, rapidly changing build plane conditions

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS11548230B2Method for determining an operational parameter for an imaging device

Publication Date: 2023.01.10 CONCEPT LASER

AI summary

Method for determining an operational parameter for an imaging device for imaging at least one part of a build plane, in particular for a determination device for determining at least one parameter of an energy beam for an apparatus for additively manufacturing three-dimensional objects, comprising the steps: determining at least one spot parameter that relates to an extension of a spot, in particular a spot of an energy beam, in a determination plane; determining a difference between the determined spot parameter and a nominal spot parameter; determining an imaging parameter of the imaging device based on the determined difference adjusting the imaging parameter based on the determined difference.