Tomographic Scanner Defect Correction Additive Manufacturing
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Solution Overview
Problem
Current additive manufacturing techniques fail to identify and correct thermal defects in objects formed through processes like selective laser melting, as these defects are dimensionally small and often located internally, making them difficult to detect until later stages of manufacturing.
Innovation Solution
A method involving tomographic scanning to create a scanner model of the object, converting it into an additive manufacturing format, comparing it to the intended 3D model to identify defects, and generating a modified 3D model to address these defects, allowing for corrections in the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional imaging systems are used during additive manufacturing, then two-dimensional layers can be monitored for accuracy, but thermal defects in the object's interior cannot be identified
Solution Approach 1:
The patent introduces tomographic scanning as an intermediary measurement technique that penetrates the object's interior to detect thermal defects. The tomographic scanner acts as a mediator between the manufactured object and the detection system, enabling visualization of internal structures without physical access or destruction of the object.
Solution Approach 2:
The patent replaces conventional mechanical imaging systems with tomographic scanning technology. Instead of using physical probes or surface-based imaging that cannot access internal defects, the system uses non-contact tomographic measurement to substitute for the inadequate mechanical detection methods.
2Reliability
If thermal defects are detected after manufacturing, then defect identification becomes possible, but the defects remain too small and internal to be practically identified
Solution Approach 1:
The patent performs tomographic scanning and defect identification during the additive manufacturing process rather than after completion. By conducting the measurement action preliminarily, the system detects thermal defects while they are still forming or immediately after formation, when they are more detectable and can be addressed before the object is fully manufactured.
Solution Approach 2:
The patent creates a digital tomographic model (copy) of the object's interior structure to analyze thermal defects. This digital replica allows for precise measurement and identification of small internal defects without physically disturbing the original object, enabling accurate defect detection through virtual inspection.
3Productivity
If current analysis techniques are used, then manufacturing process monitoring is possible, but adequate mechanisms to identify and correct thermal defects are not provided
Solution Approach 1:
The patent implements a feedback loop where tomographic scanning data is continuously fed back to the additive manufacturing control system. The identified thermal defects are used to generate corrected 3D model data that is fed back into the manufacturing process, enabling real-time correction of manufacturing parameters to prevent defect formation or compensate for detected issues.
Solution Approach 2:
The patent performs defect identification and model correction during the manufacturing process rather than after completion. By taking preliminary action to identify and correct defects while manufacturing is ongoing, the system maintains both high productivity through continuous manufacturing and high precision through immediate defect correction.
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 accurate identification and correction of thermal defects during additive manufacturing, improving the conformity of the final object to the intended design and reducing the need for destructive testing.
Implementation Method 1
scanning the portion of the object using a tomographic scanner to obtain a scanner model of the portion of the object
Implementation Method 2
The melting may be performed by a high powered laser such as a 100 Watt ytterbium laser to fully weld (melt) the metal powder to form a solid metal
Implementation Method 3
In metal powder additive manufacturing techniques, such as selective laser melting (SLM) and direct metal laser melting (DMLM), metal powder layers are sequentially melted together to form the object
Data Source
AI summary
A method for correction of thermal defects using tomographic scanning for additive manufacturing is provided. The method may include forming a portion of an object using an additive manufacturing system based on an intended three-dimensional (3D) model of the object that is in an additive manufacturing system format. The portion of the object is scanned using a tomographic scanner to obtain a model of the portion of the object in a tomographic scanner format. The model is converted from the tomographic scanner format into the additive manufacturing system format to obtain a converted tomographic model; and the converted tomographic model is compared to the intended 3D model to identify a defect in the portion of the object. A modified 3D model may be generated of the object correcting the intended 3D model to address the defect of the portion of the object.