Toolpath-Synced Z-Height Sensing for Faster 3D Printing Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing three-dimensional fabrication systems rely on expensive and slow 3D camera systems for precise layer height control, which increase processing time and costs, necessitating a more efficient and cost-effective alternative for height measurement.
Innovation Solution
A system utilizing a point z-height sensor, such as a laser triangulation sensor, attached to a tool assembly to measure surface heights in synchronization with the toolpath, with an offset distance between the fabrication and measurement spots, allowing for co-optimization of the toolpath and scanning path to enhance accuracy and reduce extra travel time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a three-dimensional camera system is used for height measurement, then measurement precision is improved, but productivity deteriorates due to slow scanning speed and high cost
Solution Approach 1:
The patent divides the measurement task from a broad three-dimensional camera scan into a focused point-by-point measurement approach using a laser triangulation sensor. The sensor measures height at specific points along the toolpath rather than scanning entire layers, segmenting the measurement process to achieve faster, more efficient height data collection while maintaining precision
Solution Approach 2:
The patent replaces the mechanical three-dimensional camera scanning system with an optical laser triangulation sensor system. This substitution uses optical principles (laser triangulation) instead of mechanical scanning, enabling real-time height measurement without the slow scanning speeds and high costs associated with three-dimensional camera systems
2Measurement precision
If a three-dimensional camera system is used for height measurement, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts only the essential height measurement function from the complex three-dimensional camera system. By using a dedicated laser triangulation sensor that measures only z-height at specific points along the toolpath, the system eliminates unnecessary complexity while maintaining the critical height measurement precision needed for layer control
Solution Approach 2:
The patent employs a relatively simple and cost-effective laser triangulation sensor instead of an expensive three-dimensional camera system. This simpler sensor provides the necessary height measurement precision at a lower cost and with reduced system complexity, making the measurement system more accessible and easier to integrate
3Productivity
If a point z-height sensor is attached to the tool assembly, then productivity is improved by simultaneous fabrication and measurement, but device complexity increases
Solution Approach 1:
The patent merges the measurement function with the fabrication tool assembly by attaching the laser triangulation sensor directly to the tool. This integration allows the sensor to follow the toolpath automatically during fabrication, enabling simultaneous measurement and manufacturing without requiring separate measurement equipment or additional travel time
Solution Approach 2:
The tool assembly is given multi-functionality by incorporating both the fabrication capability and the height measurement capability in one integrated system. The attached laser triangulation sensor enables the tool assembly to perform both manufacturing and real-time height measurement functions, improving productivity without requiring separate dedicated measurement systems
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
This approach provides accurate and real-time height measurements, reducing printing time and costs while maintaining high quality, enabling simultaneous fabrication and measurement, and allowing for dynamic adjustments to ensure part quality.
Implementation Method 1
The point z-height sensor can be a laser triangulation sensor, optionally configured at a non-normal incidence angle
Data Source
AI summary
A system for measuring surface heights during three-dimensional fabrication is disclosed, including a point z-height sensor configured to measure a position of a tool fabrication spot on a surface being printed, an attachment mechanism for attaching the point z-height sensor to a tool assembly such that movement of the point z-height sensor remains in sync with a toolpath that may include movement of the tool assembly, and a control system configured to optimize a scan path of the tool based on measured height data and movement of the tool assembly. Implementations of system for measuring surface heights during three-dimensional fabrication may include where the tool is a printhead. Methods for measuring z-height during three-dimensional fabrication using a z-height point sensor and measuring surface height in a three-dimensional printing process are also disclosed.