Error mapping method for multi-axis additive manufacturing system

The use of multiple axis machines for direct write additive manufacturing offers the potential for the custom manufacture of a wide range of useful structures ranging from sensor on curved parts to electronics on unique shapes. The motion axis for such systems do not need the force and robustness of metal cutting applications, but the geometric requirements for electronic patterns means the machines need to compensate for a wide range of errors at micron levels. The types of errors of concern may include motion axis alignments in 5-axis and more specific printing tool or fixture variations. In order to correct for any such errors, there is a need for a mapping method that can be applied across machine platforms without the need for substantial modifications to the machines. This paper will describe the selection and application of well defined, readily available basic geometric artifacts that permit the separate mapping of key error sources in such a system. The ability to provide the error measurement using simple sensors commonly available will be contrasted to more expensive, traditional volumetric mapping methods.