US 12,103,107 B2
System and methods for compensating for calibration plate irregularities in additive manufacturing systems
Brian Scott McCarthy, Schenectady, NY (US); Eric Edward Halla, West Chester, OH (US); Thomas Charles Adcock, Glenville, NY (US); Michael Evans Graham, Slingerlands, NY (US); Andrea Marie Schmitz, Niskayuna, NY (US); and Mark Samuel Bailey, Fairfield, OH (US)
Assigned to General Electric Company, Cincinnati, OH (US)
Filed by General Electric Company, Schenectady, NY (US)
Filed on Jul. 18, 2019, as Appl. No. 16/515,470.
Prior Publication US 2021/0016394 A1, Jan. 21, 2021
Int. Cl. B23K 26/342 (2014.01); B23K 26/042 (2014.01); B23K 26/08 (2014.01); B23K 26/70 (2014.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01); B33Y 50/02 (2015.01)
CPC B23K 26/342 (2015.10) [B23K 26/042 (2015.10); B23K 26/0884 (2013.01); B23K 26/702 (2015.10); B33Y 30/00 (2014.12); B33Y 50/02 (2014.12); B33Y 10/00 (2014.12)] 14 Claims
OG exemplary drawing
 
1. A method of calibrating an additive manufacturing machine, the method comprising:
positioning a calibration plate in a coordinate measuring machine;
optically or mechanically measuring a surface of the calibration plate at a plurality of measurement points while the calibration plate is in the coordinate measuring machine to generate a surface profile of the surface of the calibration plate;
generating a correction field based at least in part on a line projected through respective ones of the plurality of measurement points and determining an intersection point of the line with a reference plane corresponding to a vertical position of a powdered build material in the additive manufacturing machine, the line representing a laser beam intersecting with the powdered build material;
transferring the calibration plate from the coordinate measuring machine to the additive manufacturing machine, the additive manufacturing machine comprising a laser device;
writing at least one fiducial mark on the surface of the calibration plate using at least one laser beam generated by the laser device;
transferring the calibration plate from the additive manufacturing machine to a calibration system;
detecting a position of the at least one fiducial mark on the surface of the calibration plate while the calibration plate is in the calibration system;
generating calibration data corresponding to the surface of the calibration plate based on the position the at least one fiducial mark;
computing a corrected position for the at least one laser beam based at least in part on a comparison of the correction field to the position of the at least one fiducial mark; and
aligning the at least one laser beam based at least in part on the corrected position.