3D Printing Optics for Support-Free Thermal Feedback Control
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Solution Overview
Problem
3D printing processes often require auxiliary supports that increase manufacturing costs and time, constrain design and materialization, and can hinder the formation of cavities and ledges, while also facing challenges in controlling microstructure formation and achieving smooth surfaces.
Innovation Solution
The use of an apparatus and system that includes an energy source, a detector, and an aberration-correcting optical arrangement to control and detect thermal radiation during the 3D printing process, allowing for the simultaneous focusing of an energy beam on the target surface and thermal radiation, which enables the reduction or elimination of auxiliary supports and improves surface smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If auxiliary supports are used in 3D printing, then structural stability during printing is improved, but manufacturing cost and time increase
Solution Approach 1:
The patent removes auxiliary supports from the 3D printing process by using a closed-loop control system with real-time optical monitoring. The system detects thermal radiation from the melt pool and adjusts printing parameters dynamically, eliminating the need for auxiliary supports while maintaining structural stability during printing.
Solution Approach 2:
The patent implements a feedback control system that uses optical detectors to monitor thermal radiation from the melt pool in real-time. This feedback enables dynamic adjustment of printing parameters, allowing the system to maintain stability without auxiliary supports and reducing post-processing time.
2Stability of the object's composition
If auxiliary supports are used in 3D printing, then structural stability during printing is improved, but design freedom is constrained
Solution Approach 1:
The patent removes auxiliary supports from the 3D printing process by using a closed-loop control system with real-time optical monitoring. The system detects thermal radiation from the melt pool and adjusts printing parameters dynamically, eliminating the need for auxiliary supports while maintaining structural stability during printing.
Solution Approach 2:
The patent dynamically adjusts printing parameters such as laser power, scanning speed, and hatching patterns based on real-time thermal radiation detection. This enables the system to accommodate complex geometries and cavities without auxiliary supports, significantly increasing design freedom.
3Manufacturing precision
If energy beam is focused on target surface, then printing precision is improved, but thermal radiation detection accuracy deteriorates due to optical aberrations
Solution Approach 1:
The patent introduces a telecentric optical system as an intermediary between the energy beam and the detector. This optical system corrects for aberrations and enables simultaneous focusing of the energy beam on the target surface and thermal radiation on the detector, resolving the contradiction between printing precision and detection accuracy.
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 reduces deformation in 3D objects, minimizes the need for auxiliary supports, and enhances the control over microstructure formation and surface quality, leading to more efficient and design-constrained 3D printing.
Implementation Method 1
an energy source configured to irradiate a pre-transformed material with an energy beam to form a transformed material as part of the three-dimensional object
Implementation Method 2
a detector configured to receive thermal radiation emerging from the transformed material
Implementation Method 3
an optical arrangement configured to adjust a first focus of the energy beam on the target surface, and maintain a second focus of the thermal radiation on the detector
Implementation Method 4
aberration-correcting optical arrangement (e.g., achromatic optical setup) operatively coupled to the detector, which aberration-correcting arrangement comprises one or more optical elements operable to maintain (i) a first focus of the energy beam on the target surface, and (ii) a second focus of at least a portion of the thermal radiation on the detector
Data Source
AI summary
The present disclosure provides three-dimensional (3D) printing methods, apparatuses, software, and systems, some of which utilize one or more detectors that may be used to detect characteristics of the 3D object, e.g., in real-time during its formation. The present disclosure provides methods, apparatuses, software, and systems for generating different cross sections of one or more energy beams used for 3D printing of the 3D object.