Systems and methods for additive manufacturing operations
AssigneeSigma Labs, Inc.
InventorsVivek R. Dave, Mark J. Cola, R. Bruce Madigan, Alberto Castro, Glenn Wikle, Lars Jacquemetton, Peter Campbell
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Abstract
This disclosure describes various system and methods for monitoring photons emitted by a heat source of an additive manufacturing device. Sensor data recorded while monitoring the photons can be used to predict metallurgical, mechanical and geometrical properties of a part produced during an additive manufacturing operation. In some embodiments, a test pattern can be used to calibrate an additive manufacturing device.
Claims20
A method for calibrating an additive manufacturing device, the method comprising:
- monitoring photons emitted as energy impacts metal powder spread across a build plane during a first additive manufacturing operation performed by a first additive manufacturing device, the monitoring being performed using one or more optical sensors;
- recording sensor data captured by the one or more optical sensors;
- identifying one or more actuations of a heat source of the first additive manufacturing device using changes in intensity from the recorded sensor data;
- counting a number of actuations of the heat source;
- calculating a first best fit curve over time based on the changes in intensity and counted number of actuations;
- comparing the first best fit curve to a second best fit curve based on sensor data collected during a second additive manufacturing operation performed by a second additive manufacturing device;
- determining differences between the first and second best fit curves;
- and
- calibrating the second additive manufacturing device using the determined differences.
A method for an additive manufacturing device, comprising:
- conducting an additive manufacturing operation to build a test part during which operating parameters of the additive manufacturing device are varied;
- absorbing photons emitted from a build plane of the additive manufacturing device using a photodiode;
- extracting features from variations in a number of photons absorbed by the photodiode, extracting features comprising:
- identifying one or more actuations of a heat source of the additive manufacturing device using changes in intensity recorded by the photodiode;
- counting a number of actuations of the heat source;
- and
- calculating a best fit curve over time for the number of actuations;
- and
- comparing the extracted features to baseline features.
A calibration system configured to measure performance of an additive manufacturing device having a heat source and a build plane, the calibration system comprising:
- an optical sensor suite configured to absorb photons emitted from the build plane during an additive manufacturing operation;
- a data storage device configured to store readings taken by the optical sensor suite;
- and
- a processor configured to:
- extract features from the stored readings by identifying one or more actuations of the heat source of the additive manufacturing device using changes in intensity recorded by the optical sensor suite, counting a number of actuations of the heat source, and calculating a best fit curve over time for the counted number of actuations;
- compare the extracted features to a set of baseline features associated with another additive manufacturing device or with the same additive manufacturing device.
Dependencies are inferred from the claim text.