Temperature Control of Digital Glass Forming Processes

Abstract

Digital Glass Forming (DGF) is a new manufacturing process for low-batch glass fabrication. The work zone temperature in DGF processes must be maintained in the glass's working range to ensure good fabrication. If the temperature is too low, the filament will not wet to the substrate or previously deposited material and, if the temperature is too high, the filament may disengage from the substrate or previously deposited material, or it may partially vaporize. In this work, a real-time temperature control system capable of synchronizing process parameter, thermal camera, and visual camera data for the DGF process is introduced. A process parameter map for a scan velocity of 0.5 mm/s is constructed, as is a data-driven dynamic temperature process model. A digital controller is designed to regulate the work zone temperature. The temperature controller is a closed loop tracking controller that adjusts the commanded laser power to regulate the measured temperature. Two sets of experiments are conducted to analyze the controller performance. In the first set of experiments, single tracks on a substrate are fabricated with constant laser power and with the closed loop temperature controller. It is seen that the closed loop controller is able to extend the process parameter map into regions where using a constant laser power will result in a failed build. In the second set of experiments, walls are fabricated. Using constant laser power results in a failed build (i.e., material vaporization at the corners and the filament prematurely detaching from the substrate) as the temperature process dynamics change with layer and at the corners. The closed loop controller successfully fabricated the wall without vaporization at the corners and premature filament detachment as the controller adjusts the laser power to account for the changing temperature process dynamics.