3D Component Build Scanning for Homogeneous 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 delaying irradiation in hot regions and adapting energy influx per unit area.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the laser beam irradiates the powder layer continuously along a standard scanning path, then the production efficiency is maintained, but large temperature gradients occur leading to cracks and material unevenness

Engineering Contradiction:

Improveproduction efficiencyVSAvoidtemperature uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system performs thermographic detection before laser irradiation to identify hot regions in advance. The scanning path is then adjusted to delay irradiation of these pre-identified hot regions, preventing temperature gradients and material defects while maintaining production efficiency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses real-time thermographic detection to monitor temperature distribution and feeds this information back to dynamically adjust the laser scanning path. This closed-loop control ensures uniform temperature profiles by adapting the irradiation sequence based on actual thermal conditions, preventing cracks and material unevenness

Inventive Principle:

Principle #23Feedback

2Productivity

If the laser power and scanning speed are increased to improve productivity, then the production speed increases, but local overheating occurs leading to burrs and material defects

Engineering Contradiction:

Improveproduction speedVSAvoidlocal overheating

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system applies different irradiation strategies to different regions based on their thermal state. Hot regions are irradiated later or with reduced energy, while cooler regions receive standard irradiation, creating locally optimized temperature profiles that prevent overheating and burr formation

Inventive Principle:

Principle #3Local quality

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 homogeneous temperature profile during the manufacturing process.

Implementation Method 1

A thermographic acquisition of the irradiation plane is provided for generating the data records

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 2

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

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 3

electron beam, laser sintering or laser melting method, in which 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

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20250162244A1Method for producing a three-dimensional component

Publication Date: 2025.05.22 CONCEPT LASER

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.