Carl Zeiss Industrial Metrology, LLC

Carl Zeiss Industrielle Messtechnik Gmbh

Ut-battelle, Inc.

Carl Zeiss Ag

Carl Zeiss Meditec Gmbh

Marcin B Bauza

Thomas Engel

Nils Haverkamp

Dominik Seitz

Tobias Held

Rainer Sagemueller

Richard H Knebel

Michael Totzeck

Matthew J Everett

Ryan Dehoff

Jochen Straub

Muzammil A Arain

Christoph Hilmar Graf Vom Hagen

Alex J Plotkowski

Diana Spengler

Edson Costa Santos

Curtis Frederick

Paul Brackman

Pradeep Bhattad

Gleiton Luiz Damoulis

Claus Hermannstaedter

Markus Birkhold

Robert Zarnetta

Jason James Tenboer

Aleksandr Lisovich

A method and an arrangement for producing a workpiece using additive manufacturing techniques involve pre-process, in-process and post-process measurement in order to determine individual characteristics of one or more workpiece layers. In particular, dimensional and/or geometrical characteristics of a workpiece layer are measured before the next workpiece layer is produced. Advantageously, production parameters are controlled in response to individual material characteristics determined prior to the production process. Also advantageously, measurement results are fed back into a production process in order to increase accuracy, reliability, repeatability and precision of the production process.

Adaptive closed-loop control of additive manufacturing for producing a workpiece

A method of producing a workpiece includes obtaining CAD data representing the workpiece in multiple workpiece layers. The CAD data includes multiple workpiece layer definitions corresponding respectively to the workpiece layers. The method includes selecting a first workpiece layer definition, preparing a powder bed of powder material on a build platform, and producing, based on the selected workpiece layer definition, a workpiece layer on the build platform by controlling a layer tool to selectively melt or sinter the powder material on the build platform. The method includes assessing the produced workpiece layer, including measuring the produced workpiece layer using a measuring head, analyzing the measurements of the produced workpiece layer, and, in response to the analysis indicating that the produced workpiece layer is defective, reprocessing the produced workpiece layer by controlling the layer tool to selectively melt or sinter the powder material on the build platform.

Method and system for producing a workpiece using additive manufacturing techniques

An apparatus includes a control system that defines a test part having multiple features of multiple feature types. The control system controls an additive manufacturing (AM) machine to print multiple copies of the test part, with each copy being printed according to a respective set of values used as printing parameters. A measurement system obtains a computed tomography (CT) image of each of the copies of the test part. An analysis system, for each of the plurality of feature types, analyzes the CT images to identify a selected set of values for the printing parameters. The analysis system identifies a portion of the CT image related to a first feature and assesses its density based on an average grayscale value. The AM machine is then controlled to print production parts according to, for each feature type of the production parts, the selected set of values for the printing parameters.

Method for rapid development of additive manufacturing parameter set

An optical coherence tomography (OCT) system () is used to inspect bonding points (A,B,C) sandwiched between two materials (layersof e.g. displays). The OCT differentiates between a bonding point, e.g. a weld, and air gaps between the two materials. The bonding points are identified as breaks in the air gap between the materials. By extracting various physical characteristics of the bonding points and the gap between the two materials, the present system determines whether the bonding is faulty.

Inspection of bonding quality of transparent materials using optical coherence tomography

A method of producing a workpiece by using additive manufacturing techniques includes obtaining CAD data representing the workpiece with workpiece layer definitions defining workpiece layers. The method includes selecting a first workpiece layer definition. The method includes preparing a powder bed of powder material on a build platform. The method includes measuring individual characteristics of the powder material on the build platform using a measuring head. The method includes producing, based on the selected workpiece layer definition, a workpiece layer on the build platform. The producing includes controlling a layer tool to selectively melt or sinter the powder material on the build platform. The producing is further based on the measured individual characteristics of the powder material to correct for detected flaws in the powder bed. The method includes selecting each one of the workpiece layer definitions and repeating the preparing, the measuring, and the producing for the selected definition.

Method and arrangement for producing a workpiece by using additive manufacturing techniques

An automobile manufacturing plant for manufacturing automobiles has a series of manufacturing sites including a part forming shop, a body shop, a paint shop and an assembly shop. Each manufacturing site is associated with a respective inspection site. The respective inspection sites provide inspection data representing at least one of dimensional characteristics, shape characteristics or surface characteristics of the car body parts, the car body, the painted car body and the car-on-wheels produced in the series of manufacturing sites. The inspection data from the plurality of inspection sites is correlated in a common data base server. Inspection sites at a later stage of the manufacturing process can use inspection data from previous stages and automatically decide whether or not a car body part, the car body, the painted car body or the car-on-wheels has to be reworked.

Automobile manufacturing plant and method

A method of producing a workpiece by using additive manufacturing techniques includes obtaining computer-aided design data representing the workpiece in multiple layers. The method includes providing build platforms and layer tools. Each layer tool is moveable relative to a respective build platform and configured to generate or solidify a material layer on the respective build platform. The method includes producing a first defined material layer of the workpiece on a first build platform by controlling a first layer tool according to a first layer definition. The method includes transferring the first defined material layer from the first build platform to a second build platform and measuring the first defined material layer using a first measuring head to measure individual characteristics. The method includes producing further material layers of the workpiece by controlling a second layer tool in accordance with further layer definitions as a function of the measured individual characteristics.

A method and an arrangement for producing a workpiece using additive manufacturing techniques involve in-process measurement in order to determine individual characteristics of one or more workpiece layers. In particular, dimensional and/or geometrical characteristics of a workpiece layer are measured before the next workpiece layer is produced. Advantageously, the measurement results are fed back into the production process in order to increase accuracy and precision of the production process.

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Plymouth, MN, United States of America

Marcin B Bauza