CN116275130A - Material increase manufacturing powder paving quality detection system and detection method - Google Patents

Material increase manufacturing powder paving quality detection system and detection method Download PDF

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Publication number
CN116275130A
CN116275130A CN202310353982.1A CN202310353982A CN116275130A CN 116275130 A CN116275130 A CN 116275130A CN 202310353982 A CN202310353982 A CN 202310353982A CN 116275130 A CN116275130 A CN 116275130A
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powder
spreading
scraper
residual
printing
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Chinese (zh)
Inventor
张志�
黄见洪
林文雄
沈在平
吴鸿春
黄李杰
陈金明
陈清付
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Fujian Institute of Research on the Structure of Matter of CAS
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Fujian Institute of Research on the Structure of Matter of CAS
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Priority to CN202310353982.1A priority Critical patent/CN116275130A/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20Direct sintering or melting
    • B22F10/28Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30Process control
    • B22F10/37Process control of powder bed aspects, e.g. density
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80Data acquisition or data processing
    • B22F10/85Data acquisition or data processing for controlling or regulating additive manufacturing processes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50Means for feeding of material, e.g. heads
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50Means for feeding of material, e.g. heads
    • B22F12/57Metering means
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/60Planarisation devices; Compression devices
    • B22F12/67Blades
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/90Means for process control, e.g. cameras or sensors
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00Processes of additive manufacturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00Apparatus for additive manufacturing; Details thereof or accessories therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00Data acquisition or data processing for additive manufacturing
    • B33Y50/02Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/25Process efficiency

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Automation & Control Theory (AREA)
  • Analytical Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Investigating Materials By The Use Of Optical Means Adapted For Particular Applications (AREA)

Abstract

The invention provides a detection method of a powder paving quality detection system for additive manufacturing, which comprises the following steps: the device comprises a powder spreading scraper, an image acquisition module, a residual powder detection module, a powder feeding device, a cylinder body, a printing bottom plate and a data processing module; the powder spreading scraper is provided with a cavity for storing printing powder, and the printing powder can be uniformly spread on the printing bottom plate when the powder spreading scraper moves; the image acquisition module is arranged above the powder spreading scraper and the residual powder detection module; the data processing module is used for comprehensively processing the information acquired by the powder spreading scraper, the image acquisition module and the residual powder detection module to obtain powder spreading quality of additive manufacturing and feeding the powder spreading quality back to the additive manufacturing equipment; the powder feeding device is arranged above the powder spreading scraper. According to the powder paving quality detection system for the additive manufacturing, the powder state in the powder paving scraper is photographed and weighed, the powder state and the powder paving quality are judged, real-time monitoring of the powder paving quality is realized, and various powder paving anomalies can be automatically processed.

Description

Material increase manufacturing powder paving quality detection system and detection method
Technical Field
The invention relates to the field of metal additive manufacturing, in particular to a powder paving quality detection system and method for additive manufacturing.
Background
Rapid additive manufacturing is a rapid prototyping technique that is driven directly by a digital model to rapidly manufacture three-dimensional physical entities of any complex shape. The basic principle of the rapid additive manufacturing adopts the manufacturing idea of layering manufacturing and layering superposition, is different from the traditional subtractive manufacturing mode, and is green intelligent additive manufacturing.
The additive manufacturing integrates virtual design and digital manufacturing, special metal materials, nonmetal materials or medical biological materials are stacked layer by layer through software and a numerical control system according to a three-dimensional model constructed on a computer, so that a solid object is manufactured, and a product can be manufactured in a short time.
In the related art, the laying quality and the utilization efficiency of the powder are affected by the laying amount of each layer of the laying doctor blade. The quality of the powder spreading influences the printing quality of the parts. The current common approach is to perform image processing by comparing the current powder-laid photograph with a standard photograph. As the size of the existing additive manufacturing equipment is larger and larger, the resolution requirement on a camera is higher and higher, and the image is larger and larger, so that the analysis and processing efficiency of the image is reduced, and the working efficiency of the equipment is affected. Moreover, as the cross section of each layer of the additive manufacturing is different, various conditions exist in the state after printing and after powder spreading, and the detection of the quality of powder spreading is influenced.
Disclosure of Invention
The present invention aims to solve at least one of the technical problems in the related art to some extent. To this end, the invention provides a powder paving quality detection system for additive manufacturing, comprising: the device comprises a powder spreading scraper, an image acquisition module, a residual powder detection module, a powder feeding device, a cylinder body, a printing bottom plate and a data processing module;
the powder spreading scraper is provided with a cavity for storing printing powder, and the printing powder can be uniformly spread on the printing bottom plate when the powder spreading scraper moves;
the image acquisition module is arranged above the powder spreading scraper and the residual powder detection module and is used for shooting powder conditions in the powder spreading scraper and the residual powder detection module;
the data processing module is used for comprehensively processing the information acquired by the powder spreading scraper, the image acquisition module and the residual powder detection module to obtain powder spreading quality of additive manufacturing and feeding back the powder spreading quality to additive manufacturing equipment;
the powder feeding device is arranged above the powder spreading scraper and is used for storing printing powder and supplementing the powder to the powder spreading scraper;
the cylinder body is a molding area for manufacturing metal additive, the printing bottom plate is used for printing parts, and the cylinder body and the printing bottom plate are both positioned below the powder spreading scraper.
According to the powder paving quality detection system for the additive manufacturing, the powder state in the powder paving scraper is photographed and weighed, the powder state and the powder paving quality are judged, real-time monitoring of the powder paving quality is realized, and various powder paving anomalies can be automatically processed.
Optionally, the powder feeding device comprises a powder feeding cylinder and a powder feeding pipe, wherein the powder feeding cylinder stores printing powder and feeds the printing powder into the cavity of the powder spreading scraper through the powder feeding pipe;
the powder spreading scraper is divided into a left cavity and a right cavity, a powder baffle plate is arranged at the lower opening of the left cavity and/or the right cavity, and the powder spreading scraper further comprises a first weighing sensor for weighing the weight of powder in the powder spreading scraper.
Optionally, the residual powder detection module includes: the powder collecting plate, the lighting module and the second weighing sensor;
the powder collecting plate is used for collecting the residual powder in the powder spreading scraper, and is a transparent plate;
the lighting module comprises a bottom lighting assembly and a side lighting assembly, wherein the bottom lighting assembly is arranged below the powder collecting plate, and a backlight lighting mode is adopted to realize the backlight shooting of powder; the side lighting assembly is arranged on the side surface above the powder collecting plate, and adopts a side light lighting mode to assist the image acquisition module in shooting powder;
the second weighing sensor is used for measuring the weight of powder on the powder collecting plate, and the residual powder detection module can realize rotation or translation.
Optionally, the residual powder detection module is provided with a static electricity removing device and an ultrasonic vibration device, and the static electricity removing device and the ultrasonic vibration device are arranged on the powder collecting plate;
the printing bottom plate can freely rise and fall layer by layer along with the increase of the printing layer number;
and a powder collecting device is arranged below the residual powder detection module.
The embodiment of the invention also provides a detection method of the additive manufacturing powder paving quality detection system, which comprises the following steps:
s1: when the system receives a powder spreading instruction, the powder feeding device supplements powder for the left cavity and the right cavity of the powder spreading scraper;
s2: the image acquisition module shoots the powder condition in the cavity of the powder spreading scraper, detects whether a powder image is uniform, if the powder image is shaded, the powder is not uniformly fed, and the powder is uniform by increasing the powder feeding amount;
s3: after a proper amount of powder is filled in the powder spreading scraper, the powder in the right cavity of the powder spreading scraper is spread to a printing area to realize powder spreading in the printing area, and when the powder spreading scraper moves to the rightmost side, the residual powder in the right cavity falls into the residual powder detection module;
s4: the image acquisition module shoots the powder condition in the residual powder detection module and detects whether the powder image is uniform;
s5: in the powder spreading quality detection process, the priority of detecting defects by the image acquisition module is higher than that of detecting defects by the powder weight; when the weight of the powder is enough but the powder spreading is uneven, the powder spreading amount is increased or an alarm prompt is given;
s6: after the detection is finished, the residual powder detection module cleans the residual powder, the powder falls into the powder collecting device for subsequent recovery, and the residual powder detection module ensures the powder to be cleaned up through the static eliminating device and the ultrasonic vibration device;
s7: the next layer of powder spreading is carried out, the powder spreading scraper moves from right to left, and powder in the cavity at the left side is spread to a printing area, so that powder spreading in the printing area is realized; when the powder spreading scraper moves to the leftmost side, the residual powder in the left cavity falls into the residual powder detection module, and the residual steps are repeated from S4 to S6.
Optionally, in S2, the method further includes:
reading a first weighing sensor in the powder spreading scraper, recording the weight W1 of the powder, if the weight W1 is smaller than a minimum weight value M1, indicating that the powder feeding is insufficient, feeding the powder again, and if the weight W1 does not reach a set value, prompting that the powder feeding device is insufficient, and supplementing the powder to the powder feeding device; if W1 is larger than the maximum weight value M2, stopping powder feeding.
Optionally, the image capturing module captures the powder condition in the residual powder detecting module and detects whether the powder image is uniform or not includes:
firstly, turning on backlight illumination, taking a highlight of a light source as a background, and taking darkness as a characteristic;
if the shot image is dark, the residual powder is enough, and the powder spreading amount of the printing area is enough;
if the shot picture is a certain position without one stripe or a plurality of stripes, detecting whether a powder spreading scraper at the corresponding position is damaged or not;
if a small area of the shot image is bright, which means that the area is insufficient in powder, detecting whether the collapse of the small area occurs in the printing area;
if the large area is highlighted, the printing area is not full of powder spread in a large range, and the powder supply is insufficient;
after the back lighting is finished, shooting by side lighting is carried out, whether the powder surface has protrusions or not is detected by measuring the light lighting, the texture change of the powder surface is detected, and if protrusions exist at a certain position, the fact that the parts are provided with the protrusions is indicated, so that more powder remains.
Optionally, the image capturing module captures the powder condition in the residual powder detecting module and detects whether the powder image is uniform further includes:
while photographing, weighing the weight W2 of the powder, if the weight of the powder is greater than a preset value M3, reducing the powder feeding amount of the powder feeding device,
if the W2 value W2 (n) of the n-th layer is larger than the W2 value W2 (n-1) of the previous layer and the difference value is larger than a preset value, checking whether the cladding layer of the printed part is higher or not;
if W2 (n) is smaller than W2 (n-1) and the difference is greater than a preset value, checking whether area collapse occurs;
wherein the ratio of W2 (n) to W2 (n-1) variation anomalies is determined by the part cross-sectional areas of the n-th and n-1 th layers and the total area of the printing area.
Optionally, after identifying the defect, judging whether the defect is in a scanning area of the part, and if the defect is not in the scanning area of the part, continuing processing; if the defect is in the scanning area of the part, further judging the type of the abnormality, and adopting different processing methods according to different types;
when the defect is detected to be insufficient in powder supply, detecting whether abnormality occurs repeatedly, and if the powder supply quantity is increased or the abnormality is detected, prompting error reporting;
when the defect is detected to be the damage of the scraper, re-laying powder; if the defect of the scraper stripe occurs, multiple times of judgment are needed, if the defect continuously occurs at the same position, the defect is caused by the damage of the powder spreading scraper, and the powder spreading scraper needs to be paused and replaced;
when the detection result is that the area collapses, the powder spreading amount is increased, and the powder is spread again;
when the detection result is that the cladding layer is higher, the powder spreading amount is reduced, and the powder spreading amount is eliminated by modifying the process parameters or the scanning strategy;
the priority level of processing defects is: the powder supply is insufficient, the scraper is damaged, the area collapses, and the cladding layer is higher.
The embodiment of the invention also provides a detection method of the additive manufacturing powder paving quality detection system, which comprises the following steps:
s21: when the system receives a powder spreading instruction, the powder feeding device supplements powder to the cavity on the right side of the powder spreading scraper;
s22: the image acquisition module shoots the powder condition in the cavity of the powder spreading scraper, detects whether a powder image is uniform, if the powder image is shaded, the powder is not uniformly fed, and the powder is uniform by increasing the powder feeding amount;
s23: after a proper amount of powder is filled in the powder spreading scraper, the powder in the right cavity of the powder spreading scraper is spread to a printing area to realize powder spreading in the printing area, and when the powder spreading scraper moves to the rightmost side, the residual powder in the right cavity falls into the residual powder detection module;
s24: the image acquisition module shoots the powder condition in the residual powder detection module and detects whether the powder image is uniform;
s25: in the powder spreading quality detection process, the priority of detecting defects by the image acquisition module is higher than that of detecting defects by the powder weight; when the weight of the powder is enough but the powder spreading is uneven, the alarm prompt of the powder spreading amount is increased;
s26: after the detection is finished, the residual powder detection module cleans the residual powder, the powder falls into the powder collecting device for subsequent recovery, and the residual powder detection module ensures the powder to be cleaned up through the static eliminating device and the ultrasonic vibration device;
s27: the powder spreading scraper moves from right to left, powder does not exist in the powder spreading scraper at the moment, so that the powder spreading is not performed during the movement, one layer of powder spreading is completed when the powder spreading scraper moves to the left side, and then the step S21 is returned to wait for a next powder spreading instruction.
Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the invention and together with the description, serve to explain the principles of the invention.
FIG. 1 is a flow chart of a method for detecting a powder paving quality detection system for additive manufacturing according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of an additive manufacturing powder paving quality detection system according to an embodiment of the present disclosure;
FIG. 3 is a schematic diagram of an additive manufacturing powder paving quality detection system according to an embodiment of the present invention during residual powder detection;
FIG. 4 is a schematic diagram of an additive manufacturing powder paving quality detection system with powder emptying according to an embodiment of the present disclosure;
fig. 5 is a schematic diagram of unidirectional powder spreading of a powder spreading quality detection system for additive manufacturing according to an embodiment of the present invention.
Detailed Description
The technical scheme of the invention will be further described in detail below with reference to specific embodiments. It is to be understood that the following examples are illustrative only and are not to be construed as limiting the scope of the invention. All techniques implemented based on the above description of the invention are intended to be included within the scope of the invention.
The present embodiment provides a system for detecting quality of additive manufacturing powder spreading, referring to fig. 2 to 5, the system for detecting quality of additive manufacturing powder spreading mainly includes: the device comprises a powder spreading scraper 1, an image acquisition module 2, a residual powder detection module 3, a powder feeding device, a cylinder body 6, a printing bottom plate 7 and a data processing module.
The powder spreading scraper 1 is provided with a cavity for storing printing powder, and the printing powder can be uniformly spread on the printing bottom plate 7 when the powder spreading scraper 1 moves; specifically, the powder spreading blade 1 is like a box, and can store a certain amount of printing powder.
The image acquisition module 2 is arranged above the powder spreading scraper 1 and the residual powder detection module 3 and is used for shooting powder conditions in the powder spreading scraper 1 and the residual powder detection module 3; wherein the image acquisition module 2 is provided with on-axis illumination.
The data processing module is used for comprehensively processing the information acquired by the powder spreading scraper 1, the image acquisition module 2 and the residual powder detection module 3 to obtain powder spreading quality of additive manufacturing and feeding the powder spreading quality back to additive manufacturing equipment;
the powder feeding device is arranged above the powder spreading scraper 1 and is used for storing printing powder and supplementing the powder to the powder spreading scraper 1; the cylinder body 6 is a molding area manufactured by metal additive, the printing bottom plate 7 is used for printing parts, and the cylinder body 6 and the printing bottom plate 7 are both positioned below the powder spreading scraper 1. The printed parts 9 and powder 8 are located above the printing floor 7.
In some embodiments, the powder feeding device comprises a powder feeding cylinder 4 and a powder feeding pipe 5, wherein the powder feeding cylinder 4 stores printing powder and feeds the printing powder into the cavity of the powder spreading scraper 1 through the powder feeding pipe 5; the powder spreading scraper 1 is divided into a left cavity 11 and a right cavity 10 so as to realize bidirectional powder spreading and improve printing efficiency. The lower opening of the left side cavity 11 and/or the right side cavity 10 is provided with a powder baffle 12 for controlling the falling of the powder. The powder spreading blade 1 further comprises a first load cell for weighing the powder in the powder spreading blade 1.
According to the powder paving quality detection system for the additive manufacturing, the powder state in the powder paving scraper is photographed and weighed, the powder state and the powder paving quality are judged, real-time monitoring of the powder paving quality is achieved, various powder paving anomalies such as insufficient powder supply can be automatically processed, re-paving can be automatically performed, and if the scraper is blocked, small area collapse and the like occur, alarm and shutdown can be timely performed, state information is recorded, and quality tracing is facilitated.
In some embodiments, the residual powder detection module 3 includes: the powder collecting plate, the lighting module and the second weighing sensor; the powder collecting plate is used for collecting the residual powder in the powder spreading scraper 1, and is preferably a transparent plate, so that illumination light can be irradiated from bottom to top, and the image capturing of the image collecting module 2 is facilitated.
The lighting module comprises a bottom lighting component and a side lighting component, the bottom lighting component is arranged below the powder collecting plate, and a backlight lighting mode is adopted to realize the backlight shooting of powder; the side lighting component is arranged on the side surface above the powder collecting plate, adopts a side lighting mode, and assists the image acquisition module 2 to shoot powder.
The second weighing sensor is used for measuring the weight of powder on the powder collecting plate, and after weighing and residual powder photographing are completed, the residual powder detection module 3 can rotate or translate, the residual powder on the powder collecting plate is cleaned, and the powder falls into the powder collecting device 13 for recycling. The residual powder detection module is provided with an electrostatic removing device and an ultrasonic vibration device, so that the powder collecting plate is ensured to be cleaned up, and the measurement precision is ensured.
In some embodiments, the residual powder detection module is provided with a static electricity removing device and an ultrasonic vibration device, and the static electricity removing device and the ultrasonic vibration device are arranged on the powder collecting plate; the printing bottom plate 7 can freely rise and fall layer by layer along with the increase of the printing layer number; a powder collecting device 13 is arranged below the residual powder detection module 3.
The present embodiment also provides a detection method of the additive manufacturing powder paving quality detection system according to any of the above embodiments, referring to fig. 1, the detection method mainly includes the following steps:
s1: when the system receives a powder spreading instruction, the powder feeding device supplements powder for the left cavity and the right cavity of the powder spreading scraper 1. Illustratively, when the system receives a powder spreading command, the powder feeding tube 5 moves to the left-hand cavity 11 of the doctor blade, the powder feeding cylinder 4 releases a fixed amount of powder, and then the powder feeding tube 5 moves to the position of the broken line in fig. 2, corresponding to the right-hand cavity 10 of the doctor blade, and the powder feeding cylinder 4 releases the same amount of powder.
S2: the image acquisition module 2 shoots the powder condition in the cavity of the powder spreading scraper 1, detects whether the powder image is uniform, if shadow exists, the powder feeding is not uniform, the powder is uniform by increasing the powder feeding amount, and the whole printing surface can be fully paved during powder spreading.
S3: after the powder spreading scraper is filled with a proper amount of powder, the powder in the right cavity of the powder spreading scraper 1 is spread to a printing area, so that the powder spreading in the printing area is realized, and when the powder spreading scraper 1 moves to the rightmost side, the residual powder in the right cavity falls into the residual powder detection module 3, as shown in fig. 3.
S4: the image acquisition module 2 photographs the powder condition in the residual powder detection module 3 and detects whether the powder image is uniform.
Specifically, the backlight illumination is turned on first, the backlight produces strong contrast, the light source is highlighted as the background, and the darkness is characterized; if the shot image is dark, the residual powder is enough, and the powder spreading amount of the printing area is enough; if a shot picture is a certain position without one stripe or a plurality of stripes, the scraper at the corresponding position is possibly damaged; if a small area of the shot image is bright, the area is insufficient in powder, and small area collapse possibly occurs in the printing area; if the large area is highlighted, the printing area is not fully spread in a large range, and insufficient powder supply is indicated. After the back light illumination is finished, shooting by side light illumination, detecting whether the powder surface has protrusions or not by measuring the light illumination, and detecting the texture change of the powder surface; if there is a protrusion at a certain location, this means that there may be a protrusion of the part at this location, resulting in more powder remaining.
Further, the weight W2 of the powder was weighed while photographing. If the weight of the powder is greater than a preset value M3, the powder feeding cylinder is indicated to be excessively filled into the scraper, and the powder feeding amount can be reduced to save the powder. In general, the weight W2 of the residual powder is not abrupt, and if the W2 value W2 (n) of the n-th layer is much larger than the W2 value W2 (n-1) of the previous layer, for example, exceeds a preset value, it may be a defect that the cladding layer of the printed part is too high. If W2 (n) is much smaller than W2 (n-1), for example, more than a predetermined value, it may be that region collapse occurs. The ratio of W2 (n) to W2 (n-1) variation anomalies is determined by the part cross-sectional areas of the n-th and n-1 th layers and the total area of the print area.
S5: in the powder spreading quality detection process, the priority of detecting defects by the image acquisition module 2 is higher than that of detecting defects by the powder weight; when the weight of the powder is enough but the powder spreading is uneven, the powder spreading amount is increased or an alarm prompt is given;
specifically, after the defect is identified, judging whether the defect is in a scanning area of the part, if the defect is not in the scanning area of the part, the final processing of the part is not affected, and the processing can be continued; if the abnormal type is in the scanning area of the part, further judging the abnormal type, and adopting different processing methods according to different types. Sometimes, a plurality of different defects may appear on the same powder spreading surface, and the priority level of the system for processing the defects is as follows: the powder supply is insufficient, the scraper is damaged, the area collapses, and the cladding layer is higher. When the detection result is insufficient powder supply, detecting whether the abnormality occurs repeatedly; if the powder feeding quantity is increased or abnormality is detected, prompting to report errors. When the detection result is that the scraper is damaged, the defect is caused by damage of the scraper, and the defect of the scraper stripe is needed to be judged for many times because the defect is possibly caused by accidental factors and the powder spreading scraper is not needed to be replaced and only needs to be spread again, if the defect continuously appears at the same position, the defect is indicated to be caused by damage of the powder spreading scraper, and the powder spreading scraper is needed to be suspended and replaced, otherwise, the powder spreading can be continued again. When the detection result is that the area collapses, the problem is solved by increasing the powder spreading amount and spreading the powder again. When the detection result is that the cladding layer is higher, the powder spreading amount is reduced in a proper amount, and the powder spreading amount is slowly eliminated by modifying the process parameters or the scanning strategy, so that the processing can be continued generally. In order to ensure the consistency of the printing effect and the printing quality, the powder is emptied after each powder spreading is finished. Avoiding the influence of the residual powder on the movement of the scraper. If the image acquisition module does not shoot the scraper, the scraper is stopped in the forming area, a return instruction needs to be sent, and if the scraper cannot return to the position under the image acquisition module, the scraper is abnormal, and the machine is stopped for alarming.
S6: after the detection is completed, the residual powder detection module 3 cleans the residual powder, and the powder falls into the powder collecting device 13 for subsequent recovery, as shown in fig. 4. The residual powder detection module 3 ensures powder cleaning through the static electricity removing device and the ultrasonic vibration device, and ensures measurement precision.
S7: the powder baffle plate 12 moves to the right side to wait for the next layer of powder spreading, the next layer of powder spreading scraper 1 moves from right to left, and the powder in the cavity at the left side is spread to a printing area, so that the powder spreading of the printing area is realized; when the powder spreading scraper 1 moves to the leftmost side, the powder remained in the left cavity falls into the residual powder detection module 3, the residual steps are repeated from S4 to S6, and after the completion, the process returns to the step S1 to wait for the next powder spreading instruction. I.e. one-time powder supplementing, and two layers of powder spreading are carried out.
In some embodiments, in S2, further comprising: reading a first weighing sensor in the powder spreading scraper 1, recording the weight W1 of the powder, if the weight W1 is smaller than a minimum weight value M1, indicating that the powder feeding is insufficient, feeding the powder again, and if the weight W1 does not reach a set value, prompting that the powder feeding device is insufficient, and supplementing the powder to the powder feeding device; if W1 is larger than the maximum weight value M2, stopping powder feeding.
The embodiment of the invention also provides a detection method of the additive manufacturing powder paving quality detection system according to any of the above embodiments, and the main difference between the detection method in the above embodiment is steps S21 and S27.
Specifically, the detection method mainly comprises the following steps:
s21: when the system receives a powder spreading instruction, the powder feeding device supplements powder to the cavity on the right side of the powder spreading scraper 1;
s22: the image acquisition module 2 shoots the powder condition in the cavity of the powder spreading scraper 1, detects whether a powder image is uniform, if shadow exists, the powder feeding is not uniform, and the powder is uniform by increasing the powder feeding amount;
s23: after a proper amount of powder is filled in the powder spreading scraper, the powder in the right cavity of the powder spreading scraper 1 is spread to a printing area, so that the powder spreading in the printing area is realized, and when the powder spreading scraper 1 moves to the rightmost side, the residual powder in the right cavity falls into the residual powder detection module 3;
s24: the image acquisition module 2 shoots the powder condition in the residual powder detection module 3 and detects whether the powder image is uniform;
s25: in the powder spreading quality detection process, the priority of detecting defects by the image acquisition module 2 is higher than that of detecting defects by the powder weight; when the weight of the powder is enough but the powder spreading is uneven, the powder spreading amount is increased or an alarm prompt is given;
s26: after the detection is finished, the residual powder detection module 3 cleans the residual powder, the powder falls into the powder collecting device 13 for subsequent recovery, and the residual powder detection module 3 ensures the powder to be cleaned up through the static eliminating device and the ultrasonic vibration device;
s27: the powder spreading scraper 1 moves from right to left, and powder does not exist in the powder spreading scraper 1 at the moment, so that the powder spreading is not performed during the movement, and when the powder spreading scraper 1 moves to the left, one layer of powder spreading is completed, and then the step S21 is returned to wait for a next powder spreading instruction. I.e. supplementing the powder once, and paving the powder on one layer.
The additive manufacturing powder paving quality detection system and the detection method in the embodiment have at least the following technical effects:
(1) The powder state and the powder paving quality are judged by photographing and weighing the powder state in the powder paving scraper, so that the real-time monitoring of the powder paving quality is realized, and various powder paving anomalies can be treated autonomously; if the powder supply is insufficient, the automatic re-paving can be automatically performed, if the scraper is blocked, the small area collapses and the like, the machine can be timely alarmed and stopped, the state information is recorded, and the quality tracing is convenient.
(2) According to the detection method, when powder is filled into the powder spreading scraper, the supply amount of the powder can be judged, the uniformity of the powder is judged, problems can be found in advance, abnormality can be detected when the powder is not spread, time is saved, the utilization rate of equipment and the powder is improved, and the forming quality of parts is improved.
(3) The detection method of the embodiment can be compatible with unidirectional and bidirectional powder paving, so that the application of the system and the method is wider and is not limited.
(4) According to the residual powder detection module, the abnormality of powder spreading can be detected according to the amount of residual powder, the amount of powder feeding can be adjusted according to the weights of the image acquisition module and the weighing sensor, the utilization rate of powder is improved, and the optimal powder spreading state is realized.
(5) According to the detection method of the embodiment, various anomalies of powder spreading are detected through different shooting of side light and backlight and weighing of weight, and different processing modes are adopted for different anomalies, so that the quality of powder spreading in additive manufacturing is detected, and the requirements of industrial application are met.
In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings are merely for convenience in describing the present invention and simplifying the description, and do not indicate or imply that the device or element being referred to must have a specific orientation, be configured and operated in a specific orientation, and therefore should not be construed as limiting the present invention.
Furthermore, the terms "first," "second," and the like, are used for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include at least one such feature. In the description of the present invention, the meaning of "plurality" means at least two, for example, two, three, etc., unless specifically defined otherwise.
In the present invention, unless explicitly specified and limited otherwise, the terms "mounted," "connected," "secured," and the like are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally formed; may be mechanically connected, may be electrically connected or may be in communication with each other; either directly or indirectly, through intermediaries, or both, may be in communication with each other or in interaction with each other, unless expressly defined otherwise. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art according to the specific circumstances.
In the present invention, unless expressly stated or limited otherwise, a first feature "up" or "down" a second feature may be the first and second features in direct contact, or the first and second features in indirect contact via an intervening medium. Moreover, a first feature being "above," "over" and "on" a second feature may be a first feature being directly above or obliquely above the second feature, or simply indicating that the first feature is level higher than the second feature. The first feature being "under", "below" and "beneath" the second feature may be the first feature being directly under or obliquely below the second feature, or simply indicating that the first feature is less level than the second feature.
For purposes of this disclosure, the terms "one embodiment," "some embodiments," "example," "a particular example," or "some examples," etc., mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, schematic representations of the above terms are not necessarily directed to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, the different embodiments or examples described in this specification and the features of the different embodiments or examples may be combined and combined by those skilled in the art without contradiction.
While embodiments of the present invention have been shown and described, it should be understood that the above embodiments are illustrative and not to be construed as limiting the invention, and that variations, modifications, alternatives, and variations may be made to the above embodiments by those skilled in the art within the scope and spirit of the invention, and any such modifications, equivalents, improvements, etc. are intended to be included within the scope of the present invention.

Claims (10)

1. An additive manufacturing powder paving quality detection system, comprising: the device comprises a powder spreading scraper (1), an image acquisition module (2), a residual powder detection module (3), a powder feeding device, a cylinder body (6), a printing bottom plate (7) and a data processing module;
the powder spreading scraper (1) is provided with a cavity for storing printing powder, and the printing powder can be uniformly spread on the printing bottom plate (7) when the powder spreading scraper (1) moves;
the image acquisition module (2) is arranged above the powder spreading scraper (1) and the residual powder detection module (3) and is used for shooting powder conditions in the powder spreading scraper (1) and the residual powder detection module (3);
the data processing module is used for comprehensively processing the information acquired by the powder spreading scraper (1), the image acquisition module (2) and the residual powder detection module (3), so as to obtain powder spreading quality of additive manufacturing and feeding back the powder spreading quality to additive manufacturing equipment;
the powder feeding device is arranged above the powder spreading scraper (1) and is used for storing printing powder and supplementing the powder to the powder spreading scraper (1);
the cylinder body (6) is a forming area for manufacturing metal additive, the printing bottom plate (7) is used for printing parts, and the cylinder body (6) and the printing bottom plate (7) are both positioned below the powder spreading scraper (1).
2. Additive manufacturing powder paving quality detection system according to claim 1, characterized in that the powder feeding device comprises a powder feeding cylinder (4) and a powder feeding tube (5), the powder feeding cylinder (4) storing printing powder and feeding printing powder into the cavity of the powder paving doctor blade (1) through the powder feeding tube (5);
powder spreading scraper (1) divide into left side cavity (11) and right side cavity (10), left side cavity (11) and/or right side cavity (10) lower opening is provided with shelves powder board (12), powder spreading scraper (1) still including being used for weighing powder weight in powder spreading scraper (1) first weighing sensor.
3. Additive manufacturing powder paving quality detection system according to claim 1, characterized in that the residual powder detection module (3) comprises: the powder collecting plate, the lighting module and the second weighing sensor;
the powder collecting plate is used for collecting the residual powder in the powder spreading scraper (1), and is a transparent plate;
the lighting module comprises a bottom lighting assembly and a side lighting assembly, wherein the bottom lighting assembly is arranged below the powder collecting plate, and a backlight lighting mode is adopted to realize the backlight shooting of powder; the side lighting component is arranged on the side surface above the powder collecting plate, and adopts a side lighting mode to assist the image acquisition module (2) in shooting powder;
the second weighing sensor is used for measuring the weight of powder on the powder collecting plate, and the residual powder detection module (3) can rotate or translate.
4. A additive manufacturing powder paving quality detection system according to claim 3, wherein the residual powder detection module is provided with a static removing device and an ultrasonic vibration device, the static removing device and the ultrasonic vibration device being arranged on the powder collecting plate;
the printing bottom plate (7) can freely lift and descend layer by layer along with the increase of the printing layer number;
and a powder collecting device (13) is arranged below the residual powder detection module (3).
5. A method of detecting an additive manufacturing powder paving quality detection system according to any of claims 1-4, comprising the steps of:
s1: when the system receives a powder spreading instruction, the powder feeding device supplements powder for the left cavity and the right cavity of the powder spreading scraper (1);
s2: the image acquisition module (2) shoots the powder condition in the cavity of the powder spreading scraper (1), detects whether a powder image is uniform, if the powder image is shaded, the powder is not uniformly fed, and the powder is uniform by increasing the powder feeding amount;
s3: after a proper amount of powder is filled in the powder spreading scraper, the powder in the right cavity of the powder spreading scraper (1) is spread to a printing area to realize powder spreading in the printing area, and when the powder spreading scraper (1) moves to the rightmost side, the residual powder in the right cavity falls into the residual powder detection module (3);
s4: the image acquisition module (2) shoots the powder condition in the residual powder detection module (3) and detects whether the powder image is uniform;
s5: in the powder spreading quality detection process, the priority of detecting defects by the image acquisition module (2) is higher than that of detecting defects by the weight of powder; when the weight of the powder is enough but the powder spreading is uneven, the powder spreading amount is increased or an alarm prompt is given;
s6: after the detection is finished, the residual powder detection module (3) cleans the residual powder, the powder falls into the powder collecting device (13) for subsequent recovery, and the residual powder detection module (3) ensures the powder to be cleaned up through the static eliminating device and the ultrasonic vibration device;
s7: the next layer of powder spreading is carried out, the powder spreading scraper (1) moves from right to left, and powder in the cavity at the left side is spread to a printing area, so that the powder spreading of the printing area is realized; when the powder spreading scraper (1) moves to the leftmost side, the powder remained in the left cavity falls into the residual powder detection module (3), and the residual steps are repeated from S4 to S6.
6. The method of claim 5, further comprising, in S2:
reading a first weighing sensor in the powder spreading scraper (1), recording the weight W1 of the powder, if the weight W1 is smaller than a minimum weight value M1, indicating that the powder feeding is insufficient, feeding the powder again, and if the powder feeding is not enough, prompting that the powder feeding device is insufficient and supplementing the powder to the powder feeding device; if W1 is larger than the maximum weight value M2, stopping powder feeding.
7. The detection method of an additive manufacturing powder paving quality detection system according to claim 5, wherein the image capturing module (2) captures a powder condition in the residual powder detection module (3) and detects whether a powder image is uniform includes:
firstly, turning on backlight illumination, taking a highlight of a light source as a background, and taking darkness as a characteristic;
if the shot image is dark, the residual powder is enough, and the powder spreading amount of the printing area is enough;
if the shot picture is a certain position lacking one stripe or a plurality of stripes, detecting whether the powder spreading scraper (1) at the corresponding position is damaged;
if a small area of the shot image is bright, which means that the area is insufficient in powder, detecting whether the collapse of the small area occurs in the printing area;
if the large area is highlighted, the printing area is not full of powder spread in a large range, and the powder supply is insufficient;
after the back lighting is finished, shooting by side lighting is carried out, whether the powder surface has protrusions or not is detected by measuring the light lighting, the texture change of the powder surface is detected, and if protrusions exist at a certain position, the fact that the parts are provided with the protrusions is indicated, so that more powder remains.
8. The detection method of an additive manufacturing powder paving quality detection system according to claim 7, wherein the image capturing module (2) captures a powder condition in the residual powder detection module (3) and detects whether a powder image is uniform further includes:
while photographing, weighing the weight W2 of the powder, if the weight of the powder is greater than a preset value M3, reducing the powder feeding amount of the powder feeding device,
if the W2 value W2 (n) of the n-th layer is larger than the W2 value W2 (n-1) of the previous layer and the difference value is larger than a preset value, checking whether the cladding layer of the printed part is higher or not;
if W2 (n) is smaller than W2 (n-1) and the difference is greater than a preset value, checking whether area collapse occurs;
wherein the ratio of W2 (n) to W2 (n-1) variation anomalies is determined by the part cross-sectional areas of the n-th and n-1 th layers and the total area of the printing area.
9. The method of claim 5, wherein,
after the defects are identified, judging whether the defects are in the scanning area of the part, and if the defects are not in the scanning area of the part, continuing processing; if the defect is in the scanning area of the part, further judging the type of the abnormality, and adopting different processing methods according to different types;
when the defect is detected to be insufficient in powder supply, detecting whether abnormality occurs repeatedly, and if the powder supply quantity is increased or the abnormality is detected, prompting error reporting;
when the defect is detected to be the damage of the scraper, re-laying powder; if the defect of the scraper stripe occurs, multiple times of judgment are needed, if the defect continuously occurs at the same position, the defect is caused by the damage of the powder spreading scraper, and the powder spreading scraper needs to be paused and replaced;
when the detection result is that the area collapses, the powder spreading amount is increased, and the powder is spread again;
when the detection result is that the cladding layer is higher, the powder spreading amount is reduced, and the powder spreading amount is eliminated by modifying the process parameters or the scanning strategy;
the priority level of processing defects is: the powder supply is insufficient, the scraper is damaged, the area collapses, and the cladding layer is higher.
10. A method of detecting an additive manufacturing powder paving quality detection system according to any of claims 1-4, comprising the steps of:
s21: when the system receives a powder spreading instruction, the powder feeding device supplements powder to the cavity on the right side of the powder spreading scraper (1);
s22: the image acquisition module (2) shoots the powder condition in the cavity of the powder spreading scraper (1), detects whether a powder image is uniform, if the powder image is shaded, the powder is not uniformly fed, and the powder is uniform by increasing the powder feeding amount;
s23: after a proper amount of powder is filled in the powder spreading scraper, the powder in the right cavity of the powder spreading scraper (1) is spread to a printing area to realize powder spreading in the printing area, and when the powder spreading scraper (1) moves to the rightmost side, the residual powder in the right cavity falls into the residual powder detection module (3);
s24: the image acquisition module (2) shoots the powder condition in the residual powder detection module (3) and detects whether the powder image is uniform;
s25: in the powder spreading quality detection process, the priority of detecting defects by the image acquisition module (2) is higher than that of detecting defects by the weight of powder; when the weight of the powder is enough but the powder spreading is uneven, the powder spreading amount is increased or an alarm prompt is given;
s26: after the detection is finished, the residual powder detection module (3) cleans the residual powder, the powder falls into the powder collecting device (13) for subsequent recovery, and the residual powder detection module (3) ensures the powder to be cleaned up through the static eliminating device and the ultrasonic vibration device;
s27: the powder spreading scraper (1) moves from right to left, powder does not exist in the powder spreading scraper (1) at the moment, so that powder is not spread when the powder spreading scraper (1) moves to the left, one layer of powder spreading is completed, and then the step S21 is returned to wait for a next powder spreading instruction.
CN202310353982.1A 2023-04-04 2023-04-04 Material increase manufacturing powder paving quality detection system and detection method Pending CN116275130A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN117058154A (en) * 2023-10-13 2023-11-14 西安空天机电智能制造有限公司 Defect identification method, system and medium for 3DP metal printing powder spreading process

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN117058154A (en) * 2023-10-13 2023-11-14 西安空天机电智能制造有限公司 Defect identification method, system and medium for 3DP metal printing powder spreading process
CN117058154B (en) * 2023-10-13 2024-03-12 西安空天机电智能制造有限公司 Defect identification method, system and medium for 3DP metal printing powder spreading process

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