Nondestructive Testing Specimen Method of Manufacture and System
Patent Number: US 12190019 Grant Date: 2025-01-07 Filing Date: 2022-11-03
Overview
Filed on November 03, 2022 and granted on January 07, 2025, this patent protects a manufacturing system that produces nondestructive testing (NDE) specimens with precisely located, controllable flaws created by laser virtographing. Inventors based in Friendswood, TX developed a workflow that combines CAD/CNC control, a 3D digital flaw map, and a high‑energy beam CNC to introduce micro‑fractured defects and surface engravings in materials such as crystal, borosilicate glass, and acrylic. By selecting materials with refraction and acoustic properties analogous to industrial metals (Snell’s law considerations and ultrasonic velocity/attenuation), the specimens emulate real-world pipe and weld defects while remaining easier to fabricate and, when transparent, visually instructive for trainees. The filing demonstrates methodical claim drafting for both the virtographing process (density-controlled micro-fractures that read as reflective surfaces to inspection equipment) and an integrated specimen-manufacturing system with CAD and CNC software coordination. Our prosecution captured both the technical depth of material selection and the practical benefits of grid-aligned, curved-geometry specimens for qualification and calibration.
Key Features
- 3D digital flaw map (x, y, z) fed to CAD/CNC controller
- Virtographing with indexed energy points to create starburst micro‑fractures
- Material selection tuned to match refraction/acoustic behavior of metals
- Curved and layered specimens for weld and pipe simulation
This patent advances reproducible NDE training and calibration, improving inspection fidelity across industries that rely on ultrasonic and optical inspection techniques.
Invention Details
Abstract: A method of manufacture for creating an NDE test specimen with predictably located one or more flaws according to a digital flaw map and of a material having an angle of refraction matching industrial workpieces for testing and training is disclosed. Comprising selecting a workpiece material for the NDE test specimen having a substantially similar angle of refraction to industrial workpieces, fabricating the NDE test specimen from the workpiece material, executing a CAD software on one or more processors of a controller computer, reading the digital flaw map comprising coordinates of the one or more flaws to be applied to the NDE test specimen, controlling a high energy beam CNC to apply the digital flaw map to the NDE test specimen, selecting the workpiece material among crystal, borosilicate glass, and acrylic, applying a laser beam at a plurality of energy points within the NDE test specimen.
Summary of the Invention: A method of manufacture for creating an NDE test specimen with predictably located one or more flaws according to a digital flaw map for training user of and testing results from an NDE testing equipment is disclosed. Comprising selecting a workpiece material for said NDE test specimen comprising an angle of refraction substantially like an industrial equipment material typically inspected by said NDE testing equipment, fabricating said NDE test specimen from said workpiece material, executing a CAD software and a CNC software on one or more processors of a controller computer, reading said digital flaw map comprising coordinates of said one or more flaws to be applied to said NDE test specimen with said CAD software, controlling a high energy beam CNC with said CNC software to apply said digital flaw map to said NDE test specimen, selecting said workpiece material among crystal, borosilicate glass, and acrylic. applying a laser beam at a plurality of energy points within a portion of said NDE test specimen using said high energy beam CNC, micro-fracturing a portion of an internal volume of said NDE test specimen to create a plurality of micro-fractured flaws using a virtographing process, and applying said laser beam according to said digital flaw map to create said plurality of micro-fractured flaws. Said high energy beam CNC comprises a laser system for generating said laser beam. Said digital flaw map comprises a 3D matrix comprising location and intensity data in an x-axis, a y-axis and a z-axis.
Said method of manufacture for creating said NDE test specimen with predictably located said one or more flaws according to said digital flaw map for training user of and testing results from said NDE testing equipment is disclosed.
Patent Document
Related: Computer Science & Software | Mechanical Engineering | Consumer Products | Materials | Software And Electronics | Testing And Measurement | Friendswood, Texas | Shannon Warren, Patent Attorney