# US 10,766,200 B2 · Method and system for adjusting an additive manufacturing device

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- Number: US 10,766,200 B2
- Document ID: US10766200B2
- Status: Granted
- Kind: B2
- Application number: 16/064,446
- Filed: 2016-12-31
- Published: 2019-06-27
- Granted: 2020-09-08
- Earliest claimed: 2015-12-31
- Assignees: Ecole Centrale De Nantes
- Applicants: Ecole Centrale De Nantes
- Inventors: Jean-Yves Hascoet; Gilles Carabin
- Web page: https://patentgrep.com/patent/US10766200B2

## CPC

- B29C 64/393: for controlling or regulating additive manufacturing processes
- B05B 7/228: {using electromagnetic radiation, e.g. laser}
- B22F 10/25: Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
- B22F 10/31: Calibration of process steps or apparatus settings, e.g. before or during manufacturing
- B22F 12/53: Nozzles
- B22F 12/90: Means for process control, e.g. cameras or sensors
- B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting
- B29C 64/268: using laser beams; using electron beams [EB]
- B33Y 50/02: for controlling or regulating additive manufacturing processes
- G05B 19/18: Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of program data in numerical form (G05B19/418 takes precedence)
- G05B 19/401: characterised by control arrangements for measuring, e.g. calibration and initialisation, measuring workpiece for machining purposes (G05B19/19 takes precedence)
- G06T 7/001: {using an image reference approach}
- G06T 7/62: of area, perimeter, diameter or volume
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- 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)
- B05B: SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES (spray-mixers with nozzles B01F25/72; processes for applying liquids or other fluent materials to surfaces by spraying B05D)
- 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
- 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)
- G06T: IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A system to adjust and measure an additive manufacturing device via the CLAD method. The system includes a powder spray nozzle and a laser beam passing through the center of the nozzle, and a light source providing a light beam substantially perpendicular a lighting plane. The light source includes a support to position the light source with respect to a material surface. A profile camera is installed such that its optical axis is substantially parallel to the lighting plane. A projector to project a view seen by the center of the nozzle on an optical path and an optical axis of a centering camera is placed on the optical path. A low-power laser shot perforates a target. An acquisition and processing unit collects the images from the two cameras.

## Claims

### Claim 1

A method for adjusting and measuring a material spray/fuse device via a direct additive laser construction method utilizing a system comprising:
a powder spray nozzle;
a laser beam passing through a center of the powder spray nozzle;
a light source to provide a light beam substantially perpendicular to a lighting plane, and comprising a support to position the light source with respect to a material surface;
a first profile camera installed such that its optical axis is substantially parallel to the lighting plane;
a projector to project a view seen by the center of the powder spray nozzle on an optical path;
a centering camera with its optical axis placed on the optical path;
a target markable by a laser shot and
an acquisition and processing unit configured to collect images from the first profile camera and the centering camera;
the method comprising steps of:
positioning the powder spray nozzle above the lighting plane according to an orientation that is substantially normal to the lighting plane;
placing the target between an outlet of the powder spray nozzle and the lighting plane such that the target intercepts the laser shot;
delivering the laser shot to the target by a laser, the laser beam passing through the center of the powder spray nozzle;
lighting an end of the powder spray nozzle by the light source; and
obtaining an image, through the end of the powder spray nozzle by the centering camera, of a mark left by the laser shot on the target while the end of the powder spray nozzle is lit.

### Claim 2 (depends on 1)

The method according to claim 1, wherein the target is on the end of the powder spray nozzle.

### Claim 3 (depends on 1)

The method according to claim 1, wherein the target is held on the lighting plane.

### Claim 4 (depends on 1)

The method according to claim 1, further comprising steps of measuring a centering error between a contour of an image of the lighted end of the powder spray nozzle and the image of the mark left by the laser on the target; and
calculating an adjustment to correct the centering error by the acquisition and processing unit.

### Claim 5 (depends on 1)

The method according to claim 1, further comprising steps of spraying a stream of powder from the powder spray nozzle and obtaining an image of the stream of powder sprayed from the powder spray nozzle by the first profile camera.

### Claim 6 (depends on 5)

The method according to claim 5, further comprising steps of determining, from the image of the stream of powder obtained by the first profile camera, a shape of the stream of powder in accordance with a predetermined profile;
and determining tool gauges corresponding to the stream from the determined shape of the stream.

### Claim 7 (depends on 5)

The method according to claim 5, further comprising steps of:
generating the laser beam during spraying of the stream of powder;
measuring, on the image of the stream of powder obtained by the first profile camera, an orientation deviation of the image of the stream of powder with respect to an image of the laser; and
determining adjustments to be carried out to correct the orientation deviation of the laser beam with respect to the stream of powder.

### Claim 8 (depends on 7)

The method according to claim 7, further comprising steps of obtaining an image of the stream of powder by a second profile camera, an optical axis of the second profile camera is parallel to the lighting plane and perpendicular to the first profile camera; measuring, on the image of the stream of powder obtained by the second profile camera, the orientation deviation of the image of the stream of powder with respect to an image of the laser; and determining adjustments to be carried out to correct the orientation deviation of the laser beam with respect to the stream of powder.

### Claim 9 (depends on 8)

The method according to claim 8, comprising steps determining, from the image of the stream of powder obtained by the second profile camera, a shape of the stream of powder in accordance with a predetermined profile; and determining tool gauges corresponding to the stream from the determined shape of the stream.

### Claim 10 (depends on 1)

The method according to claim 1, wherein the light source comprises a plurality of light-emitting diodes according to an annular arrangement in the lighting plane.

### Claim 11 (depends on 2)

The method according to claim 2, where in the system further comprises a second profile camera with its optical axis parallel to the lighting plane and perpendicular to the first profile camera.