3D Layered Shaping With Laser Boundary Removal
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Solution Overview
Problem
Existing methods for manufacturing three-dimensional shaped objects using laser irradiation of powder layers often result in increased processing complexity and reduced manufacturing accuracy due to protruding portions, which can lead to decreased quality and increased processing loads.
Innovation Solution
A method involving layer formation with a material containing powder and binder, followed by a removal step where a portion of the boundary region is irradiated with a laser to remove excess material, and a melting and solidifying step to prevent protruding portions, thereby maintaining manufacturing accuracy and reducing processing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sucking and removing processing and cutting processing are performed to manufacture high-quality three-dimensional shaped objects, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent combines the removal processing and cutting processing into a single laser irradiation step. By controlling laser parameters (power, speed, pattern), the laser simultaneously removes excess powder from the boundary region and cuts the surface of the three-dimensional shaped object, eliminating the need for separate processing equipment and steps while maintaining high manufacturing precision
Solution Approach 2:
The laser device is designed to perform multiple functions: it forms layers by melting powder, removes excess material from boundary regions, and cuts surfaces. This multi-functional approach consolidates what would traditionally require separate specialized equipment into a single versatile laser system, reducing device complexity while preserving quality
2Manufacturing precision
If multiple processing steps are performed to remove powder and cut surfaces, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
Multiple processing operations (powder removal and surface cutting) are merged into a single laser irradiation step. The laser beam is controlled to simultaneously perform boundary region material removal and surface cutting, reducing the total number of processing cycles and improving productivity while maintaining precision
Solution Approach 2:
The laser processing is performed continuously in a single pass through the layer, rather than requiring separate sequential operations. The laser beam traverses the layer once, simultaneously removing powder and cutting surfaces along its path, eliminating idle time between operations and maintaining continuous productive action
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 the production of high-quality three-dimensional shaped objects with reduced processing steps, preventing protruding portions and maintaining accuracy, while considering laser irradiation as a single processing step.
Implementation Method 1
a removal step of removing a portion of the material in a boundary region including at least one of an end portion of a shaping region of the three-dimensional shaped object in the layer and an outer portion of the shaping region adjacent to the end portion by irradiating the boundary region with a laser
Implementation Method 2
a melting and solidifying step of melting and solidifying the material after melting in the shaping region by performing the irradiation with the laser
Data Source
AI summary
A method of manufacturing a three-dimensional shaped object in which the three-dimensional shaped object is manufactured by laminating layers includes: a layer formation step of forming layers using a material containing powder and a binder; a removal step of removing a portion of the material in a boundary region including at least one of an end portion of a shaping region of the three-dimensional shaped object in the layer and an outer portion of the shaping region adjacent to the end portion by irradiating the boundary region with a laser; and a melting and solidifying step of melting and solidifying the material after melting in the shaping region by performing irradiation with the laser.