# US 10,118,341 B1 · Calibration system and method for additive manufacturing devices

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- Number: US 10,118,341 B1
- Document ID: US10118341B1
- Status: Granted
- Kind: B1
- Application number: 14/804,204
- Filed: 2015-07-20
- Granted: 2018-11-06
- Earliest claimed: 2014-07-18
- Assignees: Full Spectrum Laser LLC
- Applicants: Full Spectrum Laser, LLC
- Inventors: Henry Liu; Mark P. Woodward; Rodney Chang; Nathan Rowe
- Web page: https://patentgrep.com/patent/US10118341B1

## CPC

- B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting
- B22F 10/31: Calibration of process steps or apparatus settings, e.g. before or during manufacturing
- B22F 12/49: Scanners
- B22F 12/90: Means for process control, e.g. cameras or sensors
- B29C 64/00: Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C 64/386: Data acquisition or data processing for additive manufacturing
- B29C 64/393: for controlling or regulating additive manufacturing processes
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 50/00: Data acquisition or data processing for additive manufacturing
- G01D 18/00: Testing or calibrating apparatus or arrangements provided for in groups G01D1/00 - G01D15/00
- G05B 17/00: Systems involving the use of models or simulators of said systems (G05B13/00, G05B15/00, G05B19/00 take precedence)
- G05B 17/02: electric
- G05B 19/401: characterised by control arrangements for measuring, e.g. calibration and initialisation, measuring workpiece for machining purposes (G05B19/19 takes precedence)
- G05B 19/4099: Surface or curve machining, making three-dimensional [3D] objects, e.g. desktop manufacturing
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B33Y 10/00: Processes of additive manufacturing
- B33Y 50/02: for controlling or regulating additive manufacturing processes
- G01B 11/005: {coordinate measuring machines}
- G05B 2219/36415: Adjust path and attitude tool by detecting path, line with a photosensor, laser
- G05B 2219/37571: Camera detecting reflected light from laser
- G06F 30/00: Computer-aided design [CAD]
- Y02P 10/25: Process efficiency
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- G01D: MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G)
- G01B: MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G06F: ELECTRIC DIGITAL DATA PROCESSING (computer systems based on specific computational models G06N)
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

An additive manufacturing device calibration system and method. In laser control systems, such as the laser control systems used for SL and SLS 3D printers, the laser beam is moved to a location by applying a control value. Often the control value and the location of the laser beam are in different spaces. One calibration system and method involves the input of a number of control values and their corresponding laser beam locations, and the adjusting of the parameters of a mapping function such that the control values generated by applying the mapping function to the input laser beam locations best matches the corresponding input control values.

## Claims

### Claim 1

An additive manufacturing device calibration method comprising:
(i) collecting a number of laser locations on a build surface of said additive manufacturing device and corresponding control values of said laser locations necessary to direct a laser to said laser locations;
(ii) applying a function fitting algorithm to an unfitted mapping function utilizing said laser locations and said corresponding control values to generate a calibration data set of laser locations and corresponding control values wherein said calibration data set permits control values to be generated from other laser locations not yet collected; and
(iii) moving a laser to a desired laser location by applying mapping to said desired laser location to generate a necessary control value.

### Claim 2 (depends on 1)

The additive manufacturing device calibration method of claim 1 further comprising automatically collecting said laser locations on said build surface of said additive manufacturing device and corresponding control values of said laser locations.

### Claim 3 (depends on 2)

The additive manufacturing device calibration method of claim 2 further comprising utilizing photosensors positioned on said build surface.

### Claim 4 (depends on 1)

The additive manufacturing device calibration method of claim 1 further comprising randomly and automatically collecting said laser locations on said build surface of said additive manufacturing device and corresponding control values of said laser locations.

### Claim 5 (depends on 4)

The additive manufacturing device calibration method of claim 4 further comprising utilizing photosensors positioned on said build surface.

### Claim 6 (depends on 1)

The additive manufacturing device calibration method of claim 1 further comprising utilizing a manual system for collecting said laser locations on said build surface of said additive manufacturing device and corresponding control values of said laser locations.

### Claim 7 (depends on 6)

The additive manufacturing device calibration method of claim 6 further comprising utilizing a substrate depicting said laser locations on said build surface wherein said substrate is dimensioned to at least partially cover said build surface.

### Claim 8 (depends on 1)

The additive manufacturing device calibration method of claim 1 further comprising utilizing a 2nd order polynomial as said unfitted mapping function.

### Claim 9 (depends on 1)

The additive manufacturing device calibration method of claim 1 further comprising utilizing a linear regression as said function fitting algorithm.

### Claim 10 (depends on 1)

The additive manufacturing device calibration method of claim 1 further comprising collecting said control values in the form of galvanometer voltages.

### Claim 11

An additive manufacturing device system comprising:
a laser;
a laser steering system for controlling a direction of focus of said laser;
a build surface;
an interface; and
computer instructions configured to:
(i) collect a number of laser locations on said build surface and corresponding control values of said laser locations necessary to direct said laser to said laser locations; and
(ii) apply a function fitting algorithm to an unfitted mapping function utilizing said laser locations and said corresponding control values to generate a calibration data set of laser locations and corresponding control values wherein said calibration data set permits control values to be determined from other laser locations not yet collected.

### Claim 12 (depends on 11)

The additive manufacturing device system of claim 11 wherein said computer instructions are further configured to: automatically collect said laser locations on said build surface and said corresponding control values.

### Claim 13 (depends on 11)

The additive manufacturing device system of claim 11 further comprising photosensors configured to position on said build surface.

### Claim 14 (depends on 11)

The additive manufacturing device system of claim 11 further comprising a substrate depicting laser locations on said build surface wherein said substrate is dimensioned to at least partially cover said build surface.

### Claim 15 (depends on 11)

The additive manufacturing device system of claim 11 wherein said computer instructions are further configured to: utilize a 2nd order polynomial as said unfitted mapping function.

### Claim 16 (depends on 11)

The additive manufacturing device system of claim 11 wherein said computer instructions are further configured to: apply a linear regression as said function fitting algorithm.

### Claim 17 (depends on 11)

The additive manufacturing device system of claim 11 wherein said laser steering system includes galvanometers and said collected and yet to be collected control values are based on galvanometer voltages.

### Claim 18

An additive manufacturing device system comprising:
a laser;
a laser steering system for controlling a direction of focus of said laser;
a build surface;
a substrate depicting multiple marks representing laser locations on said build surface;
an interface allowing a user to manually direct the laser to said marks on said substrate as said substrate rests on said build surface; and
computer instructions configured to:
(i) collect control values as said laser is directed at each of said marks; and
(ii) apply a function fitting algorithm to an unfitted mapping function utilizing said laser locations, associated with each of said marks, and said corresponding control values to generate a calibration data set of laser locations and corresponding control values wherein said calibration data set permits control values to be determined for other laser locations not identified by a mark on said substrate.

### Claim 19 (depends on 18)

The additive manufacturing device system of claim 18 wherein said substrate further depicts guide arrows between marks thereon.

### Claim 20 (depends on 18)

The additive manufacturing device system of claim 18 wherein said substrate is dimensioned to at least partially cover said build surface.

### Claim 21 (depends on 18)

The additive manufacturing device system of claim 18 wherein said computer instructions are further configured to: utilize a 2nd order polynomial as said unfitted mapping function.

### Claim 22 (depends on 18)

The additive manufacturing device system of claim 18 wherein said computer instructions are further configured to: apply a linear regression as said function fitting algorithm.

### Claim 23

An additive manufacturing device system comprising:
a laser;
a laser steering system for controlling a direction of focus of said laser;
a build surface;
a series of photosensors for use on said build surface;
an interface; and
computer instructions configured to:
(i) collect control values as said laser is directed automatically at each of said photosensors; and
(ii) apply a function fitting algorithm to an unfitted mapping function utilizing laser locations associated with each of said photosensors and said corresponding control values to generate a calibration data set of laser locations and corresponding control values wherein said calibration data set permits control values to be determined for other laser locations not identified by a photosensor on said build surface.