Our systems are build from individual modules providing different functions. We arrange these in concentric rings around the nozzle to be able to cover all directions to provide fast and continuous performance.
To adapt to different extruder sizes the ring diameter can be easily adjusted by increasing or decreasing the number of modules.
This provides adaptability to different hardware configurations and to dynamic process conditions without any tool steering, moving parts or changes to the Gcode.
The emitter modules in the array are arrange to create a continuous illuminated ring around the nozzle in the layer plane with overlapping the spots. This overlap boosts the power and makes the width of the heated area easily scalable by activating multiple emitters.
We’ve tested extrusion widths from 3 to 30 mm with our standard 3 active emitter setup, but this can easily be scaled to 50mm and more.
A system for smaller extrusion widths is already under development allowing for line widths as small as 0.6 mm.
Our standard emitters have been assessed for light safety and can easily be implemented in production environments.
The safety requirements are similar to wire arc welding, a process that most producing companies are familiar with.
No laser safety cell is required, drastically simplifying the implementation and reducing the cost.
With cameras in all directions the system automatically selects the camera closest to the area of interest, ensuring a direct and unobstructed view at near constant angles.
This allows us to measure the temperature continuously and consistently under the same conditions.
As the field of view exceeds the melt pool, the system is able to measure the temperature response to the heaters as well as the incoming substrate temperature simultaneously. Enabling a more accurate and independent control of multiple mechanisms at the same time.
Because accurate measurements are the foundation for precise temperature control loops.
The temperature measurement can continuously be fed back to the machine controller, either as temperature for internal processing or pre-processed as feed rate override. This enables the machine to automatically adjust itself for smarter processing.
Instead of working with constant layer times it enables the enforcement of constant layer temperatures, which ensure part stability.
Unlike layer times this constraint is independent of wall thickness and layer height, making it faster to calibrate and more robust for complex geometries with varied wall thickness.
The temperature can also be used to adaptively control cooling elements like pressurized air nozzles or fans that allow faster and more localized response to local overheating. By closing the control loop the system never undercools the part, preventing negative effects to layer adhesion and maximizing process robustness.
By combining adaptive cooling width the dynamic feed rate adjustment the machine can also self optimize it’s productivity by maximizing the feed rate and compensating with added cooling before reducing feed again.
Tests showed a potential productivity gain of over 300% on parts at risk of overheating, without any signs of slumping.
All data measured, calculated and set is stored by the system and matched to the tool position resulting in easy to interpret 3D point clouds that can be used to identify the root causes underlying any defects found on the physical part in the digital twin.
As contact temperatures correlate strongly with interlayer strength, this data can also be used for data driven quality assurance. Easily identify critical process conditions by setting thresholds and highlighting any out-of-spec conditions during printing. Whether on a visible surface or hidden within, without destructive testing.
Industrial Edge is an open, ready-to-use edge computing platform consisting of applications, OT and IT connectivity, devices, and a central management system for each of these. It makes software and data handling scalable, secure, and easy to use on the factory floor.
Use IT on the shop floor to leverage machine and plant data, optimizing operations, reducing costs, and increasing uptime. Centrally manage connected devices and software across machines, lines and plants to easily deploy apps at scale, from hundreds of ecosystem partners, making the most of your machines data.
