Computed Tomography Additive Manufacturing Presented By Josh Schradin AGENDA WHAT IS COMPUTED TOMOGRAPHY WHAT ARE THE BASIC COMPONENTS OF A CT SYSTEM AND HOW DOES IT WORK WHAT IS MAGNIFICATION AND WHY IS IT IMPORTANT ID: 911412
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Slide1
INTRODUCTION
Industrial 3D X-Ray CT (Computed Tomography)Additive Manufacturing
Presented By: Josh Schradin
Slide2AGENDA
WHAT IS COMPUTED TOMOGRAPHY?
WHAT ARE THE BASIC COMPONENTS OF A CT SYSTEM AND HOW DOES IT WORK?
WHAT IS MAGNIFICATION AND WHY IS IT IMPORTANT?
WHAT ARE VOXELS?
APPLICATIONS AND HOW IT IS USED FOR ADDITIVE MANUFACTURING
Slide3DEFINITION
WHAT IS “COMPUTED TOMOGRAPHY”? -according to Wikipedia
A CT scan, also called
X-ray Computed Tomography
(
X-ray CT
) and
Computerized Axial Tomography scan
(
CAT scan
),
makes use of computer-processed combinations of many X-ray images taken from different angles to produce cross-sectional (tomographic) images ( or
virtual "slices"
)
of specific areas of a scanned object, allowing the user to see inside the object without cutting.
Slide4WHAT ARE THE BASIC COMPONENTS OF A CT SYSTEM?
X-Ray Source
Detector
Sample on Rotary table
Slide5RECONSTRUCTION: PROJECTIONS
1 PROJECTION
2 PROJECTIONS
4 PROJECTIONS
8 PROJECTIONS
16 PROJECTIONS
ALL PROJECTIONS
The reconstruction process is taking multiple images of the object at multiple angles (or
projections
) around the object. You can see what any given projection looks like in the example below.
For any given angle, the projection is a line of brighter and darker pixels depending on how much attenuation (loss of intensity) blocks that part of the x-ray beam.
Slide6RECONSTRUCTION: VOXELS
Once the complete projections of the part are captured though a 360 degree rotation, the images are segmented into grayscale value pixels. Because the same theoretical point was captured from multiple angles thought the rotation, they can be resolved as 3D volumetric pixels, or
voxels.
A: Typical Voxel
B: Voxel Set
C: Voxel Grid
Slide7MAGNIFICATION
MAGNIFICATION is the process of moving the object closer or further away X-ray source and detector creating a larger than life size shadow which will give you higher resolution allowing us to see smaller defects and in greater detail.
Having the object closer to the detector provides a smaller shadow, decreasing the resolution of the final images
Moving the object closer to the X-Ray source provides a larger shadow, optimizing the resolution of the final images
Slide8NOW WHAT?: CT APPLICATIONS
DEFECT ANALYSIS/POROSITY
DIMENSIONAL ANALYSIS
LAYER SHIFT IN PRINTED PART
INTERNAL WALL THICKNESS OR AIR GAP
INTERNAL VISUALIZATION
TRAPPED POWDER
PRODUCT CONTENT POSITION
REVERSE ENGINEERING / MODEL OF MANUFACTURED PART
Slide9DEFECT ANALYSIS/POROSITY
EXPLORING THE COMPLETE VOLUME OF THE OBJECT ALLOWS YOU TO SEE DEFECTS IN THE OBJECT THAT TRADITIONALLY WOULD GO UNNOTICED.
IN THIS CASE, A SIMPLE CONTAINER OF LIP BALM, YOU CAN SEE A LARGE VOID IN THE MATERAL CAUSED BY THE FILLING METHOD DURING MANUFACTURING. THIS IS A VALUABLE TOOL FOR FUTURE QUALITY CONTROL.
THE VOLUME OF THE VOIDS, IN THIS CASE POROSITY, CAN BE CALCULATED TO DETERMINE RISK OF MECHANICAL FAILURE WHEN THE PART IS PUT INTO SERVICE.
MANY MANUFACTURERS HAVE STRICT RULES APPLIED TO POROSITY REGARDING QUANTITY AND SIZE.
Slide10DIMENSIONAL ANALYSIS
Used gear even shows the grease that was not cleaned off
Metrology Dimensional Layout
Blueprint
3D CAD
Reverse Engineering
CT DATA CAN BE USED TO MEASURE DIMENSIONS FROM A DRAWING TO VERIFY PART IS WITHIN SPECIFICATIONS.
Slide11DIMENSIONAL ANALYSIS CONT.
Used gear even shows the grease that was not cleaned off
Metrology Dimensional Layout
Blueprint
3D CAD
Reverse Engineering
COLOR PLOT DEVIATION TO THE NOMINAL MODEL IS ALSO HELPFUL TO VERFIY PART IN MEETING SPECIFICATIONS AND CAN ALSO BE USED TO PINPOINT ISSUES OR AREAS THAT DON’T MEET SPECIFICATION
Slide12TRAPPED POWDER & LAYER SHIFTING
Used gear even shows the grease that was not cleaned off
Metrology Dimensional Layout
Blueprint
3D CAD
Reverse Engineering
USED TO LOOK FOR TRAPPED POWDER & LAYER SHIFTS IN PRINTING PROCESS
Slide13REVERSE ENGINEERING
Used gear even shows the grease that was not cleaned off
Metrology Dimensional Layout
Blueprint
3D CAD
Reverse Engineering
NURBS MODEL
NURBS stands for ‘non-uniform rational b-splines’. This type of model consists of a curve network applied directly to a mesh controlled by allowable fit tolerances. The final surface skin (image upper right) represents the CAD surface used for downstream applications, i.e.. Machining, FEA, BUILD CORRECTIONS, etc. NURBS applied to a watertight mesh will result in a
solid
model.
Typical output: .iges, .stp, .x_t
Slide14PRODUCT CONTENT POSITION
MANUFACTURERS CAN AUDIT THEIR PRODUCTS TO DETERMINE IF EMBEDDED OBJECTS ARE GETTING DISTRIBUTED OR PLACED PROPERLY
IN THIS EXAMPLE, YOU CAN SEE THE DISTRIBUTION OF THE ALMONDS IN THE CANDY BAR, TO ENSURE THE CUSTOMER IS SATISFIED WITH EVERY BITE!
Slide15ABOUT EXACT METROLOGY
CT Scanner
Blue Light Scanner
Hand held Probing
Hand Held Scanner
Articulated Arm
CMM Retrofit
Optical Tracker
Laser Tracker
Long Range Spherical
Laser Line Scanner
EQUIPMENT
SALES
CONTRACT
SERVICES
Slide16CONCLUSION
THANK YOU!
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