3D Article Scan Sequencing for Faster Additive Manufacturing
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Solution Overview
Problem
Current additive manufacturing techniques are limited by slow production times without ensuring the quality and mechanical properties of the final three-dimensional articles, as high scan speeds can lead to excessive build temperatures affecting material properties.
Innovation Solution
The method involves increasing scan speed by interrupting adjacent scan lines between different regions of multiple articles, rotating scanning directions between layers, and using multiple energy beam sources to maintain optimal build temperatures and improve material properties, thereby reducing manufacturing time while preserving quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If scan speed is increased to reduce manufacturing time, then productivity is improved, but build temperature becomes excessively high which deteriorates material properties
Solution Approach 1:
The patent segments the scanning process by introducing intermediate scan lines between adjacent scan lines in the same article. This segmentation allows the energy beam to interrupt and cool down between adjacent scan lines, preventing excessive heat accumulation while maintaining high scan speeds for improved productivity
Solution Approach 2:
The patent extends the scanning process from a single-article sequence to a multi-article dimension. By scanning intermediate regions in other articles between adjacent scan lines of the same article, the system utilizes the temporal and spatial dimension of multiple articles to enable faster scanning without exceeding temperature limits
2Productivity
If scan speed is increased to improve productivity, then manufacturing time is reduced, but mechanical properties of the material deteriorate due to excessive build temperature
Solution Approach 1:
By segmenting the scanning sequence with intermediate scan lines in other articles, the process maintains lower build temperatures that preserve material mechanical properties while achieving high scan speeds for reduced manufacturing time
Solution Approach 2:
The patent implements periodic interruption of scan lines through intermediate scan lines in other articles. This periodic action allows rhythmic cooling between adjacent scan lines, maintaining material quality while enabling sustained high-speed scanning for improved productivity
3Productivity
If multiple articles are manufactured simultaneously to improve productivity, then manufacturing time is reduced, but process complexity increases
Solution Approach 1:
The patent makes the energy beam system universal by using the same beam to scan multiple articles in an interleaved sequence. The controlling computer manages the complex multi-article scanning schedule, while the physical apparatus remains relatively simple, achieving improved productivity through software-controlled multi-functionality
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 reduces manufacturing time while maintaining the mechanical properties and quality of the final product by optimizing scan speed and energy beam usage across multiple articles and layers.
Implementation Method 1
a ray gun for delivering energy to the powder whereby fusion of the powder takes place
Implementation Method 2
fusing a second scan line in the first article in a second direction within a predetermined time interval after fusing a first scan line in the first article in the first direction, wherein at least one intermediate scan lines is fused within the time interval at another predetermined position
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A method for forming a three-dimensional article comprising applying a first powder layer on a work table; directing a first energy causing said first powder layer to fuse in first selected locations to form a first cross section where said first energy beam is fusing a first region with parallel scan lines in a first direction and a second region with parallel scan lines in a second direction; fusing at least one of the scan lines in said first region in said first direction immediately before fusing at least one of said scan lines in said second region in said second direction; applying a second powder layer and directing the energy beam causing said second powder layer to fuse in second selected locations where the energy beam is fusing said first region with parallel scan lines in a third direction and said second region in a fourth direction.