3D Component Build Scanning for Uniform Layer Temperature
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Solution Overview
Problem
Existing electron beam and laser sintering/melting methods face challenges with large temperature gradients during the production of three-dimensional components, leading to cracks, material unevenness, and reduced accuracy.
Innovation Solution
A method that uses thermographic data to adjust the scanning path and process parameters of the laser beam, ensuring a more uniform temperature profile by avoiding initial irradiation of hot regions and adapting energy influx per unit area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the laser beam irradiates the building material layer by layer to produce three-dimensional components, then the component is created with complex geometry and customization, but large temperature gradients occur leading to cracks and reduced manufacturing precision
Solution Approach 1:
The patent applies preliminary action by pre-heating the building material layer before laser irradiation and pre-planning the scanning path to avoid hot regions initially. The control device determines in advance which regions should be irradiated first based on temperature predictions, preventing temperature gradients before they occur. This resolves the contradiction by maintaining manufacturing precision while preserving customization capability.
Solution Approach 2:
The patent implements dynamics by dynamically adjusting the scanning path and process parameters based on real-time temperature measurements from thermographic detectors. The system continuously adapts the irradiation strategy during the building process, modifying scanning speed, laser power, and path sequence to maintain uniform temperature distribution. This dynamic adaptation ensures manufacturing precision is maintained throughout the production of customized components.
2Manufacturing precision
If the laser beam is guided along a scanning path to cover the cross section completely, then the entire area is processed, but local overheating occurs leading to material unevenness and burrs
Solution Approach 1:
The patent applies feedback by using thermographic detectors to continuously measure temperature distributions during laser irradiation. The control device receives this temperature data and uses it to adjust the scanning path and process parameters in real-time. This feedback loop ensures temperature uniformity is maintained while achieving high surface quality, preventing local overheating and material unevenness.
Solution Approach 2:
The patent implements local quality by applying different irradiation strategies to different regions of the building material layer. The scanning path is specifically designed to omit high-temperature regions initially and continue irradiation at different points, while other regions receive full irradiation. This localized adaptation of the processing approach maintains temperature uniformity and prevents surface defects.
3Temperature
If thermographic detectors and adaptive control systems are added to monitor and adjust temperature profiles, then temperature uniformity is improved, but device complexity increases
Solution Approach 1:
The patent applies self-service by enabling the system to automatically monitor and adjust its own temperature distribution during the building process. The thermographic detectors continuously measure temperature profiles, and the control device autonomously determines optimized scanning paths and process parameters without external intervention. This self-regulating capability achieves temperature uniformity while minimizing the need for additional complex control infrastructure.
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 minimizes temperature gradients, prevents overheating, and enhances the quality of the produced components by maintaining a uniform temperature distribution during the manufacturing process.
Implementation Method 1
layers made of building material are applied, said layers being heated locally by the action of radiation, in particular electron or laser radiation, to solidify at the points corresponding to the cross section of the object to be produced
Implementation Method 2
there may be a connection to a layer lying therebelow
Implementation Method 3
the component is created by successively solidifying predetermined sections of individual layers of building material solidifiable by the action of an electron or laser radiation by way of fusion of the building material
Data Source
AI summary
The invention relates to a method for producing a three-dimensional component by an electron-beam, laser-sintering or laser-melting process, in which the component is created by successively solidifying predetermined portions of individual layers of building material that can be solidified by being exposed to the effect of an electron-beam or laser-beam source (2) by melting on the building material, wherein thermographic data records are recorded during the production of the layers, respectively characterizing a temperature profile of at least certain portions of the respective layer, and the irradiation of the layers takes place by means of an electron beam or laser beam (3), which is controlled on the basis of the recorded thermographic data records in such a way that a largely homogeneous temperature profile is produced, wherein, to irradiate an upper layer, a focal point (4) of the electron beam or laser beam (3) is guided along a scanning path (17), which is chosen on the basis of the data record characterizing the temperature profile of at least certain portions of the layer lying directly thereunder or on the basis of the data records characterizing the temperature profiles of at least certain portions of the layers lying thereunder.