3D Metal Printing Carriage With Parallel Lasers for Faster Layering
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Solution Overview
Problem
Existing methods for producing three-dimensional metallic shaped bodies through additive processes are slow and inefficient, particularly for large quantities, due to the need for lengthy scans and uniform layer application of metal powder, which leads to material trickle-off and uneven application, limiting their suitability for industrial mass production.
Innovation Solution
A device with a height-adjustable carriage and alternating material chambers and laser elements allows for faster application and welding of metal powder layers line-by-line, enabling simultaneous material deposition and welding in both directions, with vibration elements for uniform discharge and image generators for quality assurance, allowing for increased speed and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a uniform layer of metal powder is applied over the entire build space using a distribution tool, then material uniformity is improved, but production time increases significantly
Solution Approach 1:
The build space is divided into multiple deposition zones with alternating material chambers, allowing simultaneous material application in different regions. This segmentation enables parallel processing of multiple layers, significantly reducing total production time while maintaining uniform material distribution through coordinated control of each chamber.
Solution Approach 2:
The patent transitions from sequential single-point laser melting to multi-point simultaneous melting across multiple layers. By arranging material chambers and laser elements in alternating positions, the system applies material and melts it across multiple spatial dimensions simultaneously, eliminating the need for time-consuming sequential scanning while maintaining uniformity.
2Loss of substance
If metal powder is applied only at desired points using point-like distribution, then material waste is reduced, but material uniformity deteriorates causing trickle-off in narrow structures
Solution Approach 1:
The patent implements local quality control by assigning different material chambers to specific deposition zones based on local requirements. Each chamber can be independently controlled to deposit material with precise local uniformity, preventing trickle-off in narrow structures while avoiding waste in areas where material is not needed. The alternating arrangement allows each zone to receive optimized material application tailored to its specific geometric requirements.
3Manufacturing precision
If a distribution tool traverses the entire design area for single layer application, then material uniformity is improved, but process speed is limited by powder material inertia
Solution Approach 1:
The patent employs preliminary action by pre-positioning multiple material chambers at different locations before the melting process begins. This allows material to be deposited at multiple points simultaneously in a single pass, eliminating the need for the distribution tool to traverse the entire design area repeatedly. The alternating chamber arrangement ensures that material is already in position when laser melting occurs, achieving both uniformity and high speed.
Solution Approach 2:
The system maintains continuity of useful action by having multiple material chambers and laser elements operating simultaneously across different layers. While one chamber deposits material, another is melting it, and a third is preparing the next deposition zone. This continuous parallel operation eliminates idle traversal time and maintains constant productive action throughout the build process, achieving high speed without sacrificing uniformity.
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 significantly accelerates the manufacturing process by enabling multiple layers to be applied and welded in a single pass, reducing production time and improving the quality of the workpiece, making it more suitable for industrial-scale production.
Implementation Method 1
at least one laser element for spot-melting dispensed metal powder
Implementation Method 2
the laser can then fuse with an underlying layer to create the desired shape
Implementation Method 3
vibration elements for uniform discharge
Data Source
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AI summary
3D printers for the metal field are already known. In said printers metal powder is discharged over a base plate and relevant points are subsequently welded with the aid of a directable laser. Iteration layer-by-layer results in a shaped body which can be practically printed according to a computer model as an individual piece in the context of rapid prototyping. However, it has been established that the discharge of the metal powder, subsequent welding and final multiple iteration of this process takes up a great deal of time, making the production of the shaped body slow and time-consuming. Also, the process cannot be simply accelerated by a more rapid movement of the carriage, because of turbulence occurring in the metal powder. The invention helps to solve this problem as a laser is carried along on the carriage such that the welding process can be carried out directly with the passing over of the carriage. Therefore, the carriage can travel more rapidly without risking turbulence and also multiple layer applications are thus possible in one pass, in particular by the arrangement of parallel laser elements and material chambers across the whole width of the carriage that passes over the base plate.