2D Energy Patterning for Additive Manufacturing Bond Control
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Solution Overview
Problem
Existing additive manufacturing techniques face challenges in achieving smooth and efficient manufacturing of printed parts, particularly in overcoming activation energy barriers during the process.
Innovation Solution
The use of a system and method that incorporates two-dimensional energy patterning to both print and overcome activation energy barriers in powder bed fusion, allowing for precise control of energy distribution and efficient material processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional material removal methods (drilling, cutting, grinding) are used, then manufacturing precision can be achieved, but material waste and manufacturing time increase
Solution Approach 1:
The patent inverts the traditional manufacturing approach by using additive manufacturing (material addition) instead of subtractive manufacturing (material removal). The system deposits material layer-by-layer to build parts, fundamentally reversing the conventional process while achieving precision through controlled energy deposition and bonding.
Solution Approach 2:
The patent employs parameter changes by utilizing controlled energy input (laser or electron beam) to modify material state and bonding characteristics. By adjusting energy parameters such as power, scan speed, and focal position, the system achieves precise material deposition and bonding without mechanical contact, thereby minimizing waste while maintaining dimensional accuracy.
2Productivity
If conventional additive manufacturing is used, then material can be added layer-by-layer, but activation energy barriers slow down the manufacturing process
Solution Approach 1:
The patent applies preliminary action by pre-heating or pre-processing the material bed or deposited material to reduce the activation energy barrier before the main bonding operation. This preparatory step facilitates faster and more efficient material bonding, thereby increasing manufacturing throughput while reducing the time required to overcome energy barriers.
Solution Approach 2:
The patent utilizes periodic action through pulsed energy delivery (laser or electron beam) rather than continuous energy input. By delivering energy in controlled pulses, the system maintains material at optimal bonding temperatures, repeatedly overcomes activation energy barriers, and sustains high manufacturing throughput without excessive energy input or prolonged processing time.
3Ease of operation
If uniform energy distribution is used in powder bed fusion, then material processing is simplified, but precise control of bonding and melting is reduced
Solution Approach 1:
The patent implements local quality by distributing energy non-uniformly across the powder bed, concentrating energy precisely where material bonding or melting is required. The system modulates energy intensity locally based on the specific processing needs of different regions, enabling precise control over bonding and melting while maintaining operational simplicity through automated energy pattern control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables efficient and precise additive manufacturing by effectively overcoming activation energy barriers, leading to improved manufacturing throughput and energy efficiency.
Implementation Method 1
directing first radiant energy at a first portion of the layer; overcoming, after the amalgamating, an activation energy barrier corresponding to the first portion by directing second radiant energy thereat
Data Source
AI summary
An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. The two-dimensional energy patterning system may be used to control a state of matter of each successive additive layer. Accordingly, the system may be used to alter the chemical bond arrangement of the material forming the various additive layers.