Multi-laser multi-material laser cladding 3D printing method and system

Abstract

The invention discloses a multi-laser multi-material laser cladding 3D printing method and system, and relates to the technical field of 3D printing, and the method comprises the steps that according to a three-dimensional model of a target component, a printing path and a lap joint point position are determined; carrying out regional division on the working face; a sensor is used for detecting the thickness of each layer in real time, and the printing speed and the laser power are adjusted according to detection data; laser welding is carried out on a lap joint area between the printing layers, and laser annealing is carried out to release residual stress; and according to component requirements, different materials are dynamically switched in the printing process. The multi-printing-head and multi-laser-device cooperative work, path optimization and dynamic feedback control, material dynamic switching and laser annealing treatment technologies are adopted, and the problems of size limitation, insufficient interlayer binding force, complex material switching, path conflict and thermal stress in the large forming part manufacturing process are fundamentally solved. Compared with a traditional process, the printing efficiency, the finished product quality and the production flexibility are remarkably improved.

Description

Technical Field

[0001] The present invention relates to the field of 3D printing technology, and in particular to a multi-laser multi-material laser cladding 3D printing method and system. Background Art

[0002] In the field of traditional 3D printing technology and large-scale component manufacturing, although additive manufacturing (AM) brings process flexibility, the existing technology still has obvious limitations when dealing with oversized structural parts and complex parts made of multiple materials. These technical difficulties make it impossible for traditional methods to meet the manufacturing needs of high-strength, large-size and multi-functional parts.

[0003] First, in terms of printing size, due to the limitation of the working space of the equipment, existing 3D printing equipment can usually only print within a limited volume. For large structural parts, it is often necessary to print the parts in blocks and then assemble them through subsequent splicing and welding. However, this method is prone to stress concentration and insufficient bonding strength at the joints, resulting in the overall performance of the finished product not meeting the standards. In addition, the manual splicing process increases the production cycle and cost, and it is difficult to ensure the quality consistency of the joints.

[0004] Secondly, the path planning and control in traditional printing methods are complex. When multiple print heads or modular devices are required to print simultaneously, insufficient path planning may cause conflicts or interference in the movement paths of the print heads, affecting printing efficiency and accuracy. At the same time, when multiple devices work together, if there is a lack of effective path optimization algorithms and real-time control systems, it will lead to material waste, excessive empty paths, and equipment conflicts. These factors make it difficult for traditional methods to achieve efficient and seamless printing.

[0005] In addition, in terms of material selection and inter-layer bonding, existing technologies usually use single material printing or subsequent superposition of composite materials to achieve the functions of different areas. However, this method cannot guarantee the perfect fusion between different materials, especially for the combination of metal materials and high-strength composite materials. Insufficient bonding between layers will affect the overall structural strength of the component, and additional heat treatment or machining is required to improve the bonding performance. In addition, the manual switching of different materials in traditional processes increases the complexity of operations and the risk of errors.

[0006] Temperature stress management is also a major problem in traditional technologies. In the manufacturing process of large parts, residual stress will be generated when the material is cooled. If it is not effectively controlled, it may cause cracks or deformation in the parts. Traditional processes require a lot of pre-treatment or post-treatment processes to release stress, which increases production cycle and cost.

[0007] Therefore, the existing technology has many pain points in terms of size limitation, path planning, material diversity and stress control, resulting in low printing efficiency, poor finished product quality and high production cost. The present invention aims to solve the shortcomings of these traditional processes, and realizes efficient and precise manufacturing of large structural parts through the coordinated work of multiple print heads and lasers, path optimization and real-time adjustment, dynamic material switching, and laser welding and annealing processes, and improves the interlayer bonding force and the overall performance of the components. Summary of the invention

[0008] In view of the above-mentioned problems, the present invention is proposed.

[0009] Therefore, the technical problem solved by the present invention is: how to overcome the problems of limited printing size, insufficient interlayer bonding force, complex path planning, difficulty in switching between multiple materials and residual thermal stress when manufacturing large structural parts, so as to achieve efficient, accurate and versatile 3D printing.

[0010] In order to solve the above technical problems, the present invention provides the following technical solutions: a multi-laser multi-material laser cladding 3D printing method, which comprises the following steps:

[0011] Determine the printing path and the location of the overlap points according to the three-dimensional model of the target component;

[0012] Divide the working surface into areas and dynamically adjust the laser power and path;

[0013] Use sensors to detect the thickness of each layer in real time and adjust the printing speed and laser power based on the detection data;

[0014] Laser welding is used in the overlapped areas between printed layers, and laser annealing is performed to release residual stress;

[0015] According to component requirements, different materials are dynamically switched during the printing process to achieve local reinforcement of the structure.

[0016] As a preferred solution of the multi-laser multi-material laser cladding 3D printing method described in the present invention, wherein: determining the printing path and the overlap point position according to the three-dimensional model of the target component includes:

[0017] Use software to generate a 3D model of the component, and determine the printing path of each layer through model slicing. According to the stress analysis of the structure, select the overlap area and avoid the stress concentration area;

[0018] The path optimization algorithm is used to calculate the optimal printing path for each print head. The laser's welding path is planned synchronously with the printing path to determine the welding point covering the overlapping area.

[0019] As a preferred solution of the multi-laser multi-material laser cladding 3D printing method described in the present invention, wherein: the work surface is divided into regions, and the laser power and path are dynamically adjusted, including;

[0020] The printing surface is divided into multiple areas, each area corresponds to a print head and laser for collaborative operation. The power of the laser is dynamically adjusted according to the material thickness and melting point, and the path deviation is monitored in real time.

[0021] As a preferred solution of the multi-laser multi-material laser cladding 3D printing method described in the present invention, wherein: the real-time detection of the thickness of each layer includes:

[0022] A laser rangefinder is installed near the print head to detect the thickness of the printed layer in real time. When the thickness deviation is detected to exceed the preset threshold, the height of the print head or the power of the laser is adjusted, and the printing speed is adjusted in real time according to the feedback data to ensure consistent thickness between layers.

[0023] As a preferred solution of the multi-laser multi-material laser cladding 3D printing method described in the present invention, wherein: the laser annealing to release residual stress includes:

[0024] Pulsed laser is used for local welding in the overlap area to complete the metallurgical bonding of the materials. After the welding is completed, the laser anneals the overlap area to eliminate thermal stress and adjusts the annealing temperature and time in real time according to the material characteristics.

[0025] As a preferred solution of the multi-laser multi-material laser cladding 3D printing method described in the present invention, the dynamic switching of different materials includes:

[0026] The print head integrates multiple material nozzles, which switch the corresponding materials according to the different materials reflected in the 3D model. During the material switching process, the print head movement is paused, the nozzles are automatically cleaned, and the printing parameters are set according to the material characteristics.

[0027] As a preferred solution of the multi-laser multi-material laser cladding 3D printing method described in the present invention, wherein: the use of a path optimization algorithm to calculate the optimal printing path of each print head includes:

[0028] When multiple print heads work together, a path replanning algorithm is used to calculate the optimal path for each print head. When a path conflict is detected, non-critical tasks are automatically suspended and the current welding task is prioritized. The path adjustment data is synchronized to all devices in real time through a high-speed communication protocol.

[0029] Another object of the present invention is to provide a multi-laser and multi-material laser cladding 3D printing method system, which can avoid path conflicts when multiple print heads work together through path optimization algorithms and real-time feedback control technology, and use laser welding and annealing treatment between layers to achieve interlayer metallurgical bonding and thermal stress release, thereby greatly improving the mechanical strength and structural stability of the finished product, solving the problems of existing 3D printing technology in the manufacture of large structural parts, such as size limitations, insufficient splicing strength, difficult path planning, and complex material switching, thereby improving production efficiency and finished product quality.

[0030] In order to solve the above technical problems, the present invention provides the following technical solutions: a multi-laser multi-material laser cladding 3D printing method system, comprising: a three-dimensional modeling and path planning module, a printing and laser collaborative control module, a sensor monitoring and feedback module, and a high-speed communication and data synchronization module;

[0031] The 3D modeling and path planning module converts the printing object into a recognizable model, generates the printing path of each layer through slicing and path planning algorithms, and is responsible for real-time detection of path conflicts when multiple print heads work together, and replans the printing and welding paths;

[0032] The printing and laser collaborative control module controls the synchronous operation of multiple print heads and lasers in their respective areas, dynamically adjusts the laser power according to the material thickness and melting point, and suspends non-critical tasks when path conflicts or equipment delays are detected, and gives priority to important welding tasks;

[0033] The sensor monitoring and feedback module monitors the thickness of each layer of material through sensors to ensure the consistency of thickness between layers, detects the deviation of the printing path in real time, and feeds back the data to the control system for adjustment, monitors the temperature changes during laser welding and annealing to ensure that the stress release effect meets expectations, transmits the data collected by the sensor to the control system, and completes the real-time adjustment of the print head height, printing speed and laser power;

[0034] The high-speed communication and data synchronization module ensures the synchronization of control data between the print head and the laser, completes the coordinated adjustment of the path and power, and sends the new path data to all devices in a timely manner after the path is replanned, using high-speed communication protocols to ensure a stable connection between multiple print heads, lasers and control systems.

[0035] A computer device includes a memory and a processor, wherein the memory stores a computer program, and when the processor executes the computer program, the steps of the multi-laser multi-material laser cladding 3D printing method as described above are implemented.

[0036] A computer-readable storage medium stores a computer program, which, when executed by a processor, implements the steps of the multi-laser multi-material laser cladding 3D printing method as described above.

[0037] Beneficial effects of the invention: The multi-print head and multi-laser collaborative work, path optimization and dynamic feedback control, dynamic material switching and laser annealing treatment technology adopted by the invention fundamentally solve the size limitation, insufficient interlayer bonding, complex material switching, path conflict and thermal stress problems in the manufacture of large molded parts. Compared with traditional processes, the invention significantly improves printing efficiency, finished product quality and production flexibility. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work. Among them:

[0039] Figure 1 An overall flow chart of a multi-laser multi-material laser cladding 3D printing method provided for the first embodiment of the present invention;

[0040] Figure 2 A system diagram of a multi-laser multi-material laser cladding 3D printing method provided for the second embodiment of the present invention. DETAILED DESCRIPTION

[0041] In order to make the above-mentioned purposes, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the drawings of the specification. Obviously, the described embodiments are part of the embodiments of the present invention, but not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary persons in the art without creative work should fall within the scope of protection of the present invention.

[0042] Example 1, reference Figure 1 As one embodiment of the present invention, a multi-laser multi-material laser cladding 3D printing method is provided, comprising:

[0043] The present invention effectively solves the problems of existing 3D printing technology in the manufacture of large structural parts, such as size limitation, insufficient splicing strength, complex path planning, difficult material switching and insufficient thermal stress management, through coordinated control of multiple print heads and multiple lasers, path optimization and dynamic feedback, dynamic material switching and laser melting and annealing processes.

[0044] Determine the printing path and the location of the overlap points according to the three-dimensional model of the target component;

[0045] Divide the working surface into areas and dynamically adjust the laser power and path;

[0046] Use sensors to detect the thickness of each layer in real time and adjust the printing speed and laser power based on the detection data;

[0047] Laser welding is used in the overlapped areas between printed layers, and laser annealing is performed to release residual stress;

[0048] According to component requirements, different materials are dynamically switched during the printing process to achieve local reinforcement of the structure.

[0049] Use software to generate a 3D model of the component, and determine the printing path of each layer through model slicing. According to the stress analysis of the structure, select the overlap area and avoid the stress concentration area;

[0050] The path optimization algorithm is used to calculate the optimal printing path for each print head. The laser's welding path is planned synchronously with the printing path to determine the welding point covering the overlapping area.

[0051] It is further explained that:

[0052] When printing each layer, the slicing of the 3D model runs synchronously with the path planning algorithm to ensure that the path corresponds to the structural force analysis in real time. When new stress concentration areas or unexpected deformations are detected during printing, the system will dynamically recalculate the path and adjust the movement trajectory of the print head and laser through the path replanning algorithm. The system binds the metallurgical bonding points of the overlap area to the path planning to ensure that the laser works accurately at the fusion points between layers and reduce error accumulation.

[0053] This synchronous control system of real-time path planning and overlap point optimization effectively solves the limitations of static path planning in traditional printing methods and realizes the coordination of dynamic path adjustment and welding control.

[0054] The printing surface is divided into multiple areas, each area corresponds to a print head and laser for collaborative operation. The power of the laser is dynamically adjusted according to the material thickness and melting point, and the path deviation is monitored in real time.

[0055] A laser rangefinder is installed near the print head to detect the thickness of the printed layer in real time. When the thickness deviation is detected to exceed the preset threshold, the height of the print head or the power of the laser is adjusted, and the printing speed is adjusted in real time according to the feedback data to ensure consistent thickness between layers.

[0056] It is further explained that:

[0057] In the multi-print head and laser collaborative working system of the present invention, in order to ensure workload balance in different areas, avoid path conflicts and ensure printing quality, the system must have the ability to dynamically adjust task loads. The dynamic adjustment system is based on real-time monitoring, path replanning, feedback control and task priority management to ensure efficient collaboration of various devices and achieve high-quality printing of oversized molded parts.

[0058] The system uses a network of sensors installed on the print head and laser to monitor the task execution of each device in real time, including:

[0059] The current progress of the area that each print head is responsible for, the area of ​​the printed layer and the amount of material used; the output of the laser power and the coverage of the welding path; the status of the material nozzles of each print head to prevent downtime due to insufficient materials; the real-time detection of material layer thickness and temperature changes through laser rangefinders and temperature sensors to prevent printing deviations and poor welding.

[0060] These monitoring data will be transmitted to the central control system in real time via high-speed communication protocols as a basis for load adjustment.

[0061] Based on real-time monitoring data, the load prediction model is used to predict the task completion time and load level of each device. When a print head completes a task faster or later, the system will automatically adjust the task to ensure that all devices have a balanced load.

[0062] If a print head completes the task in its area ahead of schedule, the system will dispatch it to other areas to assist the print heads that have not yet completed their tasks. When a laser's welding task is delayed, the system will assign other lasers to provide temporary support to ensure that the welding task is completed on time.

[0063] This task adjustment avoids some equipment being idle due to underload, while ensuring that work in critical areas is not hindered.

[0064] In order to prevent path conflicts between multiple print heads and lasers, the system uses a path replanning algorithm to optimize the printing path in real time. When conflicts or interferences are detected in the device paths, the system automatically suspends non-critical tasks and gives priority to the welding tasks in the overlapped area. In addition, the system dynamically adjusts the movement trajectories of the print heads and lasers based on the path replanning results to ensure seamless connection between devices when switching tasks.

[0065] The system continuously receives feedback data during the printing process and makes real-time adjustments to the print head and laser:

[0066] When the layer thickness of a certain area is detected to be beyond the standard, the system will reduce the printing speed to ensure uniform layer thickness. If a certain area lags behind, the printing speed will be appropriately increased to ensure progress.

[0067] The power of the laser is adjusted in real time according to the material thickness and melting point. If the material layer is too thick, the laser will automatically increase the power to ensure the quality of the welding; if the power is insufficient and the welding is poor, the system will immediately supplement the welding operation.

[0068] When switching materials, the system pauses the movement of the print head and automatically cleans the nozzle to avoid material contamination. The nozzle temperature and material flow rate are automatically set according to the material characteristics to ensure a smooth transition during the switching process.

[0069] It is further explained that:

[0070] The load prediction model predicts the task load of each print head and laser in advance to avoid task imbalance and equipment idleness, and improve the overall efficiency of the system. The model is based on historical data analysis, real-time monitoring data and machine learning algorithms to dynamically predict the workload of each device and intelligently allocate tasks.

[0071] The load forecasting model needs to collect input information from multiple data sources in the system including:

[0072] The length, area, and complexity of the print paths for each layer; the number and location of overlapping areas; the type of material used and its physical properties.

[0073] The working speed, material ejection rate and layer thickness of each print head; the laser's welding power, coverage and completion progress.

[0074] Printing time and load distribution of similar structures in the past; performance of each machine in similar tasks.

[0075] The above data are input into the load prediction model, and the expected load of each print head and laser in the current task is predicted by multivariate linear regression analysis method.

[0076] Pulsed laser is used for local welding in the overlap area to complete the metallurgical bonding of the materials. After the welding is completed, the laser anneals the overlap area to eliminate thermal stress and adjusts the annealing temperature and time in real time according to the material characteristics.

[0077] It is further explained that:

[0078] In the overlap area, the laser first performs welding in high-power pulse mode to ensure metallurgical bonding between material layers. Subsequently, the laser switches to low-power continuous mode to anneal the overlap area to eliminate residual stress. Stress sensors are arranged in the overlap area to monitor the changes in internal residual stress in real time. The system dynamically adjusts the temperature and time of laser annealing based on the feedback stress data. When printing different areas, the system can set the local annealing temperature and scanning speed according to the material characteristics to avoid material deformation or performance loss caused by high temperature.

[0079] During the printing process, the stress sensor monitors the stress release of the overlap area in real time and transmits the data to the control system. If insufficient stress release is detected, the system will extend the annealing time or increase the laser power; if the temperature is too high, the system will reduce the power or speed up the scanning speed. After the high-temperature annealing is completed, the system gradually lowers the temperature and performs low-temperature annealing to avoid thermal shock of the material. After printing is completed, the system stores all annealing parameters and feedback data in the database for subsequent task optimization.

[0080] It is further explained that:

[0081] The laser automatically switches between pulse mode and continuous mode during the annealing process to adapt to the needs of different materials.

[0082] For local high-temperature annealing, the pulse mode is used to ensure rapid local heating of the material to achieve stress release in the micro-area; for large-area scanning annealing, a continuous mode laser is used with low-power continuous output to ensure uniform heating and stable cooling of the material area.

[0083] The print head integrates multiple material nozzles, which switch the corresponding materials according to the different materials reflected in the 3D model. During the material switching process, the print head movement is paused, the nozzles are automatically cleaned, and the printing parameters are set according to the material characteristics.

[0084] It is further explained that:

[0085] Each print head integrates multiple nozzles, and the material is switched through a solenoid valve. The system switches the nozzles in real time and sets the corresponding printing parameters according to the material information in the 3D model. During the material switching process, the print head pauses and automatically cleans the nozzles to prevent cross contamination. After cleaning, the system automatically calibrates the nozzle position to ensure the accuracy of material output. The system automatically adjusts the nozzle temperature and material flow rate according to the characteristics of the material to achieve a smooth transition and seamless combination between different materials.

[0086] The present invention solves the problems of material contamination and inaccurate switching in traditional multi-material printing through an automatic cleaning and calibration mechanism, and realizes more intelligent material management and switching control.

[0087] When multiple print heads work together, a path replanning algorithm is used to calculate the optimal path for each print head. When a path conflict is detected, non-critical tasks are automatically suspended and the current welding task is prioritized. The path adjustment data is synchronized to all devices in real time through a high-speed communication protocol.

[0088] It is further explained that:

[0089] The system uses a path planning algorithm to detect path conflicts between multiple print heads and lasers in real time. When a conflict is detected, the system automatically pauses non-critical tasks and prioritizes the current welding task. All path adjustments and device status are synchronized to all devices in real time through high-speed communication protocols to ensure that the collaborative work of multiple print heads and lasers is not disturbed. In the case of multiple tasks, the system will dynamically adjust the priority of printing tasks and welding tasks to ensure that tasks on the critical path are not disturbed.

[0090] The present invention solves the path conflict problem in the collaborative work of multiple devices through path replanning and data synchronization technology, and improves the collaborative efficiency between multiple print heads and lasers.

[0091] Embodiment 2 is an embodiment of the present invention, which provides a system for a multi-laser multi-material laser cladding 3D printing method, comprising: referring to Figure 2 The present invention comprises a three-dimensional modeling and path planning module, a printing and laser coordinated control module, a sensor monitoring and feedback module, and a high-speed communication and data synchronization module.

[0092] The 3D modeling and path planning module converts the printing object into a recognizable model, generates the printing path for each layer through slicing and path planning algorithms, and is responsible for real-time detection of path conflicts when multiple print heads work together, and replans the printing and welding paths.

[0093] The printing and laser collaborative control module controls the synchronous operation of multiple print heads and lasers in their respective areas, dynamically adjusts the laser power according to the material thickness and melting point, and suspends non-critical tasks when path conflicts or equipment delays are detected, and gives priority to important welding tasks.

[0094] The sensor monitoring and feedback module monitors the thickness of each layer of material through sensors to ensure consistent thickness between layers, detects deviations in the printing path in real time, and feeds the data back to the control system for adjustment. It monitors temperature changes during laser welding and annealing to ensure that the stress release effect meets expectations, transmits the data collected by the sensor to the control system, and completes real-time adjustment of the print head height, printing speed, and laser power.

[0095] The high-speed communication and data synchronization module ensures the synchronization of control data between the print head and the laser, completes the coordinated adjustment of the path and power, and sends the new path data to all devices in a timely manner after the path is replanned. It uses high-speed communication protocols to ensure a stable connection between multiple print heads, lasers and control systems.

[0096] If the functions are implemented in the form of software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, or the part that contributes to the prior art or the part of the technical solution, can be embodied in the form of a software product. The computer software product is stored in a storage medium, including several instructions for a computer device (which can be a personal computer, a server, or a network device, etc.) to perform all or part of the steps of the method described in each embodiment of the present invention. The aforementioned storage medium includes: U disk, mobile hard disk, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), disk or optical disk, etc., which can store program code.

[0097] The logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered as an ordered list of executable instructions for implementing logical functions, and can be embodied in any computer-readable medium for use by an instruction execution system, device or apparatus (such as a computer-based system, a system including a processor, or other system that can fetch instructions from an instruction execution system, device or apparatus and execute instructions), or in conjunction with such instruction execution systems, devices or apparatuses. For the purposes of this specification, "computer-readable medium" can be any device that can contain, store, communicate, propagate or transmit a program for use by an instruction execution system, device or apparatus, or in conjunction with such instruction execution systems, devices or apparatuses.

[0098] More specific examples of computer-readable media (a non-exhaustive list) include the following: an electrical connection with one or more wires (electronic device), a portable computer disk case (magnetic device), a random access memory (RAM), a read-only memory (ROM), an erasable and programmable read-only memory (EPROM or flash memory), an optical fiber device, and a portable compact disk read-only memory (CDROM). In addition, the computer-readable medium may even be a paper or other suitable medium on which the program is printed, since the program may be obtained electronically, for example, by optically scanning the paper or other medium, followed by editing, deciphering or, if necessary, processing in another suitable manner, and then stored in a computer memory.

[0099] It should be understood that the various parts of the present invention can be implemented by hardware, software, firmware or a combination thereof. In the above-mentioned embodiments, a plurality of steps or methods can be implemented by software or firmware stored in a memory and executed by a suitable instruction execution system. For example, if implemented by hardware, as in another embodiment, it can be implemented by any one of the following technologies known in the art or their combination: a discrete logic circuit having a logic gate circuit for implementing a logic function for a data signal, a dedicated integrated circuit having a suitable combination of logic gate circuits, a programmable gate array (PGA), a field programmable gate array (FPGA), etc.

[0100] Embodiment 3: In this embodiment, in order to verify the beneficial effects of the present invention, scientific demonstration is carried out through economic benefit calculation and simulation experiments. This embodiment experiments the existing traditional method and the method of this embodiment respectively.

[0101] The present invention relates to a 3D printing method for large molded parts with multiple print heads and lasers working together, aiming to solve the problems of size limitation, path conflict, insufficient interlayer bonding, complex material switching and residual stress in traditional 3D printing technology. In order to verify the effectiveness of the present invention, this simulation experiment will adopt the technical solution of the present invention to print large metal structural parts, and conduct data comparison and analysis with the printing effect of the traditional 3D printing method, and demonstrate the process advantages and beneficial effects of the present invention through simulation experiments.

[0102] In this experiment, four 3D printing heads, four laser heads, a laser rangefinder, a temperature sensor, and a stress sensor were used to print titanium alloy, aluminum alloy, and carbon fiber composite materials.

[0103] Using 3D modeling software integrated with path planning algorithms and stress analysis and thermal simulation software, a large metal frame structure measuring 1.5m x 1.5m was printed.

[0104] The conventional 3D printing method and the multi-print head laser collaborative process of the present invention were tested respectively.

[0105] The CAD software was used to generate a 3D model of a 1.5m x 1.5m metal frame structure, and the model was sliced ​​and path planned. The traditional method uses a single print head path planning, while the present invention uses a multi-print head path optimization algorithm to ensure that there is no path conflict between the print heads and preset the overlap area.

[0106] Use the load prediction model to calculate the task load of each print head and laser, and dynamically adjust the task. Monitor the status of the material nozzle to achieve automatic switching of multiple materials to ensure smooth printing of local enhancement areas.

[0107] During the printing process, sensors monitor layer thickness, temperature and path deviation data in real time. If path conflict or uneven load is detected, the system immediately replans the path and adjusts the task.

[0108] In the overlap area, the laser performs melting in pulse mode to ensure metallurgical bonding. The laser then switches to continuous mode to anneal the overlap area to release residual stress. Sensors monitor the stress release in real time and adjust the annealing temperature and time.

[0109] The specific experimental data are shown in Table 1.

[0110] Table 1 Experimental comparison data table

[0111]

[0112] It can be seen from the experimental data that the multi-print head and laser collaborative working method of the present invention is superior to the traditional 3D printing method in many aspects. First, the printing time is reduced by 40%, which is mainly due to the parallel operation of multiple print heads and the dynamic allocation of tasks. The traditional method takes longer to complete the same task due to the path planning limitations of a single print head.

[0113] In terms of path planning, the present invention uses a path optimization algorithm and a real-time replanning mechanism to effectively avoid path conflicts, while the traditional method has multiple path conflicts during the printing process, resulting in delays. At the same time, during the material switching process, the present invention shortens the switching time by 80% through automatic cleaning and nozzle calibration, significantly improving printing efficiency.

[0114] In terms of layer thickness consistency, thanks to real-time feedback and closed-loop control systems, the present invention controls the layer thickness error within ±0.05mm, which is 83% higher than the ±0.3mm error of the traditional method. This high-precision control ensures the overall quality of the printed part.

[0115] In addition, the laser pulse welding and continuous annealing process significantly reduced the residual stress in the overlap area from 100MPa to 25MPa, avoiding the risk of cracking of the structural parts. At the same time, the present invention achieves interlayer metallurgical bonding, which increases the bonding strength by 30% to 650MPa. This result shows that the present invention has significant advantages in mechanical properties and structural stability.

[0116] Table 2 Data comparison table

[0117]

[0118] According to the data in Table 2, the present invention has shown significant advantages over traditional 3D printing methods in terms of technical performance from multiple angles. First, in terms of energy consumption, the present invention reduces idle time and repeated movements through path optimization and task allocation of multiple print heads and lasers working together, reducing unit printing energy consumption by 37.5%, reflecting good energy-saving effects. In terms of material waste rate and scrap rate control, the present invention adopts sensor real-time monitoring and path replanning technology to effectively avoid waste caused by layer thickness deviation, path conflict and material switching delay. The material waste rate and scrap rate are reduced by 75% respectively, significantly improving material utilization efficiency and product qualification rate. At the same time, the present invention reduces printing costs by 33% through parallel printing, automatic material switching and efficient annealing process, making the production process more economical. In addition, in terms of thermal stress release, due to the use of switching between pulse and continuous laser modes and staged annealing control, the thermal stress release efficiency is increased from 60% of the traditional process to 90%, avoiding cracks and deformation problems caused by stress concentration, thereby greatly improving structural stability. In terms of printing accuracy, the present invention controls the layer thickness error within ±0.05mm through real-time feedback closed-loop control, which is 83% higher than the ±0.3mm error of the traditional process, ensuring the quality of the finished product of complex structural parts. In terms of response speed and system reliability, the present invention relies on high-speed communication protocols and task priority management to greatly reduce the response time of material switching and path conflicts, shortening the equipment switching time by 83%. At the same time, the system failure rate is reduced by 80% through path replanning and load balancing technology, ensuring the efficient coordination and stable operation of the equipment. Overall, the present invention is not only superior to traditional processes in production efficiency, printing accuracy and cost control, but also has achieved technological breakthroughs in material utilization, stress management and system stability, providing a reliable solution for the intelligent manufacturing of large-scale complex structural parts.

[0119] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A multi-laser multi-material laser cladding 3D printing method, characterized in that: include: Determine the printing path and the location of the overlap points according to the three-dimensional model of the target component; Divide the working surface into areas and dynamically adjust the laser power and path; Use sensors to detect the thickness of each layer in real time and adjust the printing speed and laser power based on the detection data; Laser welding is used in the overlapped areas between printed layers, and laser annealing is performed to release residual stress; According to component requirements, different materials are dynamically switched during the printing process to achieve local reinforcement of the structure.

2. A multi-laser multi-material laser cladding 3D printing method according to claim 1, characterized in that: Determining the printing path and the overlap point position according to the three-dimensional model of the target component includes: Use software to generate a 3D model of the component, and determine the printing path of each layer through model slicing. According to the stress analysis of the structure, select the overlap area and avoid the stress concentration area; The path optimization algorithm is used to calculate the optimal printing path for each print head. The laser's welding path is planned synchronously with the printing path to determine the welding point covering the overlapping area.

3. A multi-laser multi-material laser cladding 3D printing method as claimed in claim 2, characterized in that: The step of dividing the working surface into regions and dynamically adjusting the laser power and path includes: The printing surface is divided into multiple areas, each area corresponds to a print head and laser for collaborative operation. The power of the laser is dynamically adjusted according to the material thickness and melting point, and the path deviation is monitored in real time.

4. A multi-laser multi-material laser cladding 3D printing method as claimed in claim 3, characterized in that: The real-time detection of the thickness of each layer includes: A laser rangefinder is installed near the print head to detect the thickness of the printed layer in real time. When the thickness deviation is detected to exceed the preset threshold, the height of the print head or the power of the laser is adjusted, and the printing speed is adjusted in real time according to the feedback data to ensure consistent thickness between layers.

5. A multi-laser multi-material laser cladding 3D printing method as claimed in claim 4, characterized in that: The laser annealing to release residual stress comprises: Pulsed laser is used for local welding in the overlap area to complete the metallurgical bonding of the materials. After the welding is completed, the laser anneals the overlap area to eliminate thermal stress and adjusts the annealing temperature and time in real time according to the material characteristics.

6. A multi-laser multi-material laser cladding 3D printing method as claimed in claim 5, characterized in that: The dynamic switching of different materials includes: The print head integrates multiple material nozzles, which switch the corresponding materials according to the different materials reflected in the 3D model. During the material switching process, the print head movement is paused, the nozzles are automatically cleaned, and the printing parameters are set according to the material characteristics.

7. A multi-laser multi-material laser cladding 3D printing method according to claim 6, characterized in that: The method of using a path optimization algorithm to calculate the optimal printing path of each print head includes: When multiple print heads work together, a path replanning algorithm is used to calculate the optimal path for each print head. When a path conflict is detected, non-critical tasks are automatically suspended and the current welding task is prioritized. The path adjustment data is synchronized to all devices in real time through a high-speed communication protocol.

8. A system using a multi-laser multi-material laser cladding 3D printing method as claimed in any one of claims 1 to 7, characterized in that: It includes 3D modeling and path planning module, printing and laser collaborative control module, sensor monitoring and feedback module, and high-speed communication and data synchronization module; The 3D modeling and path planning module converts the printing object into a recognizable model, generates the printing path of each layer through slicing and path planning algorithms, and is responsible for real-time detection of path conflicts when multiple print heads work together, and replans the printing and welding paths; The printing and laser collaborative control module controls the synchronous operation of multiple print heads and lasers in their respective areas, dynamically adjusts the laser power according to the material thickness and melting point, and suspends non-critical tasks when path conflicts or equipment delays are detected, and gives priority to important welding tasks; The sensor monitoring and feedback module monitors the thickness of each layer of material through sensors to ensure the consistency of thickness between layers, detects the deviation of the printing path in real time, and feeds back the data to the control system for adjustment, monitors the temperature changes during laser welding and annealing to ensure that the stress release effect meets expectations, transmits the data collected by the sensor to the control system, and completes the real-time adjustment of the print head height, printing speed and laser power; The high-speed communication and data synchronization module ensures the synchronization of control data between the print head and the laser, completes the coordinated adjustment of the path and power, and sends the new path data to all devices in a timely manner after the path is replanned, using high-speed communication protocols to ensure a stable connection between multiple print heads, lasers and control systems.

9. A computer device comprising a memory and a processor, wherein the memory stores a computer program, wherein: When the processor executes the computer program, the steps of a multi-laser multi-material laser cladding 3D printing method described in any one of claims 1 to 7 are implemented.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the steps of a multi-laser multi-material laser cladding 3D printing method as described in any one of claims 1 to 7 are implemented.

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