X-Ray Reference Plate for Electron Beam Calibration in 3D Printing
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Solution Overview
Problem
Existing additive manufacturing apparatuses face challenges in accurately calibrating the position and shape of an electron beam, which is crucial for forming precise three-dimensional articles, due to the need for efficient verification methods.
Innovation Solution
An X-ray standard reference object with parallel upper and lower plates and a predetermined hollow pattern is used to calibrate the electron beam by measuring X-ray signals, allowing for accurate and easy calibration of the beam's shape and position through the knife edge beam profiling method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional calibration methods are used, then calibration can be performed, but the process is complex and time-consuming
Solution Approach 1:
The patent uses a simplified reference object with hollow patterns that copies only the essential calibration features needed for electron beam characterization, eliminating the need for complex calibration apparatus while maintaining calibration accuracy
Solution Approach 2:
The invention extracts only the critical calibration elements (hollow patterns in plates) from a complete calibration system, separating the essential measurement features from unnecessary complexity, allowing fast and simple calibration
2Measurement precision
If accurate calibration is achieved, then beam position and shape are verified, but the manufacturing cost increases
Solution Approach 1:
The reference object is designed as a simple, inexpensive item that can be easily manufactured and potentially replaced, using basic materials and straightforward construction methods while maintaining calibration accuracy
Solution Approach 2:
Instead of using expensive specialized calibration artifacts, the patent employs a simplified copied version with hollow patterns that replicates the essential calibration function at much lower cost
3Measurement precision
If the hollow pattern is complex, then calibration accuracy improves, but fabrication difficulty increases
Solution Approach 1:
The calibration reference object is divided into separate components (first plate with holes, second plate with hollow pattern, third plate) that can be manufactured independently and assembled, simplifying the fabrication of each individual part while maintaining overall calibration accuracy
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 solution provides a simple, inexpensive, and reliable method for calibrating the electron beam, ensuring high accuracy and minimizing noise signals, thereby improving the precision of three-dimensional article fabrication.
Implementation Method 1
measuring X-ray signals generated by scanning the electron beam onto the reference object
Data Source
AI summary
A standard reference plate is configured for insertion into an additive manufacturing apparatus for calibrating an electron beam of the additive manufacturing apparatus. The standard reference plate includes a lower plate and an upper plate being essentially in parallel and attached spaced apart from each other, the upper plate including a plurality of holes. A predetermined hollow pattern is provided inside the holes, and a spacing between the holes and the size of the holes and a distance between the upper plate and the lower plate and a position of an x-ray sensor of the additive manufacturing apparatus with respect to the standard reference plate are arranged so that x-rays emanating from the lower plate, when the electron beam is passing through a hollow part of the hollow pattern, will not pass directly from the lower plate through any one of the holes to the x-ray sensor.