Optical sensing techniques for calibration of an additive fabrication device and related systems and methods

• US 10,611,093 B2
• Filed: 01/09/2018
• Issued: 04/07/2020
• Est. Priority Date: 01/09/2018
• Status: Active Grant

• Current Assignee: Formlabs Incorporated
• Original Assignee: Formlabs Incorporated
• Inventors: FrantzDale, Benjamin, Keenan, Justin
• Primary Examiner(s): Nguyen, Sang H
• Application Number:
  US15/865,421
• Publication Number:
  US 20190210289A1
• Time in Patent Office: 819 Days
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: G01B 11/002 for measuring two or more coordinates

Abstract

Techniques of optically sensing fiducial targets, such as calibration patterns, within an additive fabrication device are provided. In some embodiments, fiducial targets may be disposed on a structure configured to contact source material of the additive fabrication device, the source material being a material from which the device is configured to fabricate solid objects. Indirect sensing means may be employed such that light emitted from a light source of the additive fabrication device scatters from the surface of a fiducial target. At least some of this scattered light can be measured by a sensor and used to determine a position of the fiducial target. In some embodiments, the fiducial target may be configured to move relative to the light source and/or sensor to provide additional information on the target'"'"'s position via the light scattered from its surface.

Claims

1. An additive fabrication device configured to fabricate an object by forming layers of solid material on a build platform, the solid material being formed from a liquid photopolymer, the additive fabrication device comprising:

at least one light source;

at least one sensor;

a container configured to hold the liquid photopolymer during said fabrication of the object, wherein a surface of the container includes at least a first calibration pattern;

a dispenser configured to dispense the liquid photopolymer into the container;

a build platform arranged above the container and configured to be raised and lowered into and out of the container; and

at least one processor configured to;

direct the at least one light source to the first calibration pattern;

measure, via the at least one sensor, an intensity of light scattered from the first calibration pattern; and

determine a position of the container based at least in part on the measured intensity of light.

2. The additive fabrication device of claim 1, wherein the container is configured to move relative to the build region, and wherein the at least one processor is further configured to move the container during fabrication of the object.

3. The additive fabrication device of claim 1, further comprising a mounting attachment, and wherein the container is configured to be removably attached to and detached from the mounting attachment.

4. The additive fabrication device of claim 1, comprising a source of actinic radiation arranged below the container and configured to direct actinic radiation through the container onto the liquid photopolymer held by the container.

5. The additive fabrication device of claim 4, wherein the at least one light source includes the source of actinic radiation.

6. The additive fabrication device of claim 1, wherein the first calibration pattern includes a plurality of surface features having at least two different surface reflectivities.

7. The additive fabrication device of claim 1, further comprising at least one computer readable medium, and wherein the at least one processor is further configured to store a plurality of calibration values in the at least one computer readable medium based at least in part on the determined position of the container.

8. The additive fabrication device of claim 7, wherein the plurality of calibration values include a lookup table.

9. The additive fabrication device of claim 1, wherein the at least one light source is configured to produce light at least one non-visible wavelength.

10. The additive fabrication device of claim 1, wherein the first calibration pattern is a pattern printed onto the surface of the container.

11. The additive fabrication device of claim 1, wherein the at least one processor is configured to:

direct the at least one light source over a plurality of locations on the first calibration pattern;

measure, via the at least one sensor, the intensity of light scattered from the first calibration pattern for each of the plurality of locations, thereby producing a plurality of measurements; and

determine the position of the container based at least in part on the plurality of measurements.

12. The additive fabrication device of claim 1, further comprising an adhesive sticker attached to the surface of the container, wherein the first calibration pattern is printed on the adhesive sticker.