In-Situ 3D printing and Non-Destructive Testing with Computer Tomography Using X-ray Flexible Detector

Abstract

A method of in-situ 3D printing and Non-Destructive Testing (NDT) with Computer Tomography (CT) using X-ray flexible detector is presented. An apparatus of in-situ 3D printing and NDT using CT with X-ray flexible detector comprises a 3D printer, an X-ray source, X-ray flexible detector, data acquisition system, CT reconstruction software, CT visualization software, motion control system and a computer. Either platform of 3D build object or X-ray source, X-ray flexible detector can be on a rotation and translational stage. The apparatus with the method can automatically stop current 3D printing build, replace older part and start a new object build process based on real time CT data analysis.

Claims

1. An method of In-Situ 3D printing and Non-Destructive Testing with Computer Tomography Using X-ray Flexible Detector, the method compromising: a. operating an additive manufacturing system or 3D printing system to perform a build process by building a part on a build platform, the part being built by forming a series of layers of material on the build platform, the material melting and solidifying during the build process thereby creating internal defects in the part; b. during the build process, using one or plurality of X-ray generators and one or plurality of X-ray flexible detectors to generate X-ray CT imaging data of the part; c. storing the X-ray CT imaging data in a data logger to provide stored imaging data in the data logger; and d. analysing the stored CT imaging data to determine whether a defect has formed during the build process, the method further comprising generating a warning if the analysis of the stored imaging data concludes that a defect has formed during the build process, wherein the warning includes an indication of a position in the part.

2. Apparatus for performing the method of claim 1, the apparatus comprising: a. a build platform to build a part; b. an additive manufacturing system which can be operated to perform the build process; c. a X-ray cone beam CT system with X-ray generator, X-ray flexible detector, translational and rotational motion control system, image reconstruction and visualization software to generate CT image data of the part; d. a data logger for storing the CT image data to provide stored CT image data in the data logger; and e. an analysis tool configured to analyse the stored CT image data to determine whether a defect has formed during the build process, and to generate a warning if the analysis of the stored CT image data concludes that a defect has formed during the build process, wherein the warning includes an indication of a position and a size in the part.

3. The apparatus of claim 2 wherein the indication of a position in the part indicates an X, Y, Z location of the part.

4. The apparatus of claim 2 wherein either object build platform or assembly of X-ray generator and X-ray flexible detector is on a motion control.

5. The apparatus of claim 2 wherein number of X-ray generator and X-ray flexible detector is with either single piece or a plurality of pieces.

6. The apparatus of claim 2 wherein there is a sub-structure to stop build process.

7. The apparatus of claim 2 wherein there is a sub-structure to remove the old part and mount a new part.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] FIG. 1 is a schematic of one embodiment of an apparatus for in-situ 3D printing and NDT with CT using X-ray flexible detector in accordance with the invention.

[0029] FIG. 2 is a schematic of an alternative embodiment of an apparatus for in-situ 3D printing and NDT with CT using X-ray flexible detector in accordance with the invention.

[0030] FIG. 3 is a schematic of an alternative embodiment of an apparatus for in-situ 3D printing and NDT with CT using X-ray flexible detector in accordance with the invention.

[0031] FIG. 4 is a schematic of an alternative embodiment of an apparatus for in-situ 3D printing and NDT with CT using X-ray flexible detector in accordance with the invention.

[0032] FIG. 5 is a schematic showing an X-ray flexible detector can be obtained by bending a straight detector into a curved geometry with specific radius.

SUMMARY OF THE INVENTION

[0033] Generally, current invention relates to a method and a system that can provide simultaneous quality assurance of in-situ additive manufacturing during a 3D printing build process.

[0034] In particular, the quality assurance method uses X-ray Computer Tomography (CT) with X-ray flexible panel detector have non-contact, non-destructive features and can be put into automation so that large volume of high quality objects can be produced. So X-ray CT with X-ray flexible panel detector can be much easier integrated into a 3D printing system.

[0035] Either platform of 3D build or X-ray source, X-ray detector can be on a rotation and translational stage.

[0036] Using CT computer control, if defects are found in the part being built in-progress, this 3D printing process can be terminated in early stage; older part can be replaced and a new 3D printing process can be started.

BRIEF DESCRIPTION OF THE DRAWINGS

[0037] FIG. 1 is a schematic of one embodiment of an apparatus for simultaneous 3D printing and NDT with CT using X-ray flexible detector in which the 3D platform stands still while X-ray source and X-ray flexible detector rotate and move up-down together.

[0038] FIG. 2 is a schematic of an alternative embodiment of an apparatus for simultaneous 3D printing and NDT with CT using X-ray flexible detector in which the 3D printing platform rotates and X-ray source moves up-down along with X-ray flexible detector.

[0039] FIG. 3 is a schematic of an alternative embodiment of an apparatus for simultaneous 3D printing and NDT with CT using X-ray flexible detector in which X-ray source and X-ray detector stand still while the 3D platform rotates and moves up-down.

[0040] FIG. 4 is a schematic of an alternative embodiment of an apparatus for simultaneous 3D printing and NDT with CT using X-ray flexible detector in which the 3D printing platform moves up-down while X-ray source and X-ray flexible detector rotate.

[0041] FIG. 5 shows that a straight X-ray detector is being made into an X-ray flexible detector, readout electronics PCB part is at non-flexible part while active pixel and X-ray scintillator becomes flexible part.

DETAILED DESCRIPTION OF THE INVENTION

[0042] The present invention is a method and a system to perform in-situ 3D printing and X-ray NDT simultaneously.

[0043] The system to perform the method comprises X-ray source 4 to produce X-ray beam 5, X-ray flexible detector 6, 3D printing head 3, 3D printing object 1 and 3D printing platform 2.

[0044] Depending on different working modes, there are rotational and translational motion control mechanisms.

[0045] Referring to FIG. 1, it is one of working modes. 3D printing platform 2, 3D printing object 1 and 3D printing head 3 stand still while X-ray source 4 and X-ray flexible detector 6 can rotate and move up-down together.

[0046] FIG. 2 shows another working mode. 3D printing platform 2, 3D printing object 1 and 3D printing head 3 rotate while X-ray source 4 and X-ray flexible detector 6 move up-down.

[0047] FIG. 3 is yet another working mode. X-ray source 4 and X-ray flexible detector 6 stand still while 3D print platform 2, 3D printing object 1 and 3D printing head 3 rotates and move up-down.

[0048] FIG. 4 is still another working mode. 3D printing platform 2, 3D printing object 1 and 3D printing head 3 move up-down while X-ray source 4 and X-ray flexible detector 6 rotates.

[0049] FIG. 5 shows how to make an X-ray flexible detector 6 from a straight detector. X-ray flexible detector 6 has to use a flexible substrate. Then attachment a layer of GOS scintillator in front of TFT layer would make detector X-ray sensitive. Usually the layer of GOS scintillator is facing X-ray beam. Because both substrate layer and scintillator are flexible so the active pixel part of X-ray detector becomes flexible. Radius of X-ray flexible detector 6 can be easily adjusted based on X-ray-source-to-detector distance.