US 11,941,568 B2Granted

Method for quality monitoring of additive manufacturing processes

OwnerMark I. Norfolk, Adam J. Hehrinventors

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Abstract

A method for quality control monitoring of additive manufacturing processes comprising forming at least one channel in an additive manufacturing build platform, wherein the channel is formed in the upper surface of the build platform to a predetermined depth, and wherein the channel is formed in a predetermined pattern across the upper surface of the build platform; placing a sensor in the channel formed in the upper surface of the build platform, wherein the sensor gathers information relevant to an additive manufacturing process occurring on or in close proximity to the build platform; enclosing the sensor within the channel formed in the upper surface of the build platform with an additive manufacturing substrate, wherein components or parts are built directly on the substrate using an additive manufacturing process, and using the sensor to gather information about the components or parts and the additive manufacturing process itself.

Claims20

Dependent claims

A method for quality control monitoring of additive manufacturing processes, comprising:

(a) forming at least one channel in an additive manufacturing build platform having an upper surface and a lower surface,
(i) wherein the channel is formed in the upper surface of the additive manufacturing build platform;
(ii) wherein the at least one channel is formed to a predetermined depth in the upper surface of the additive manufacturing build platform, and
(iii) wherein the at least one channel is formed in a curvilinear pattern across the upper surface of the additive manufacturing build platform;
(b) placing a sensor in the at least one channel formed in the upper surface of the additive manufacturing build platform, wherein the sensor is operative to gather information relevant to an additive manufacturing process occurring on the additive manufacturing build platform;
(c) enclosing the sensor within the at least one channel formed in the upper surface of the additive manufacturing build platform with an additive manufacturing substrate having a predetermined thickness,
(i) wherein components or parts are built directly on the additive manufacturing substrate using an additive manufacturing process, and
(d) using the enclosed sensor to gather information about the components or parts and the additive manufacturing process used to build the components or parts.

5 more elements

A method for quality control monitoring of additive manufacturing processes, comprising:

(a) forming a plurality of channels in an additive manufacturing build platform having an upper surface and a lower surface,
(i) wherein each channel is formed in the upper surface of the additive manufacturing build platform;
(ii) wherein each channel is formed to a predetermined depth in the upper surface of the additive manufacturing build platform, and
(iii) wherein each channel is formed in a curvilinear pattern across the upper surface of the additive manufacturing build platform;
(b) placing a sensor in each channel formed in the upper surface of the additive manufacturing build platform, wherein each sensor is operative to gather information relevant to an additive manufacturing process occurring on the additive manufacturing build platform;
(c) enclosing each sensor within each channel formed in the upper surface of the additive manufacturing build platform with an additive manufacturing substrate having a predetermined thickness,
(i) wherein the additive manufacturing substrate is formed by depositing successive layers of metal on the upper surface of the additive manufacturing build platform using an ultrasonic additive manufacturing process, and
(ii) wherein components or parts are built directly on the additive manufacturing substrate using an additive manufacturing process, and
(d) using the enclosed sensor to gather information about the components or parts and the additive manufacturing process used to build the components or parts.

6 more elements

A method for quality control monitoring of additive manufacturing processes, comprising:

(a) forming a plurality of channels in an additive manufacturing build platform having an upper surface and a lower surface,
(i) wherein each channel is formed in the upper surface of the additive manufacturing build platform;
(ii) wherein each channel is formed to a predetermined depth in the upper surface of the additive manufacturing build platform, and
(iii) wherein each channel is formed in a curvilinear pattern across the upper surface of the additive manufacturing build platform;
(b) placing a sensor in each channel formed in the upper surface of the additive manufacturing build platform, wherein each sensor is operative to gather information relevant to an additive manufacturing process occurring on the additive manufacturing build platform;
(c) enclosing each sensor within each channel formed in the upper surface of the additive manufacturing build platform with an additive manufacturing substrate having a predetermined thickness,
(i) wherein the additive manufacturing substrate is formed by depositing successive layers of metal on the upper surface of the additive manufacturing build platform using an ultrasonic additive manufacturing process, and
(ii) wherein components or parts are built directly on the additive manufacturing substrate using an additive manufacturing process, and
(d) using the enclosed sensor to gather information about the components or parts and the additive manufacturing process used to build the components or parts;
(e) mounting the additive manufacturing build platform, sensor, and additive manufacturing substrate directly within an additive manufacturing system;
and
(f) connecting a computer or data processor to the sensor, wherein the computer or data processor further includes software for analyzing data collected by the sensor.

9 more elements

Dependencies are inferred from the claim text.

Facts

Application: 17/679,833Filed 24 Feb 2022 · continuation
Priority: 4 Dec 2019
Published: US 2022/0288845 A115 Sep 2022
Granted: 26 Mar 2024
Term ends: Not estimatedThe source records don’t support an estimate.

Classification32 codes

G06Q 10/06395
Performance analysis of employees; Performance analysis of enterprise or organisation operations: quality analysis or management
B22F 10/85
Data acquisition or data processing: for controlling or regulating additive manufacturing processes
B22F 12/90
Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive…: means…
B29C 64/194
Involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control: during lay-up