Additive Manufacturing Allocation for Continuous Build Packing
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Solution Overview
Problem
Existing additive manufacturing processes are inefficient due to the need to interrupt ongoing processes to add new objects, leading to reduced packing density and quality issues.
Innovation Solution
A method and device for controlling multiple additive manufacturing apparatuses that allow objects to be assigned automatically without interrupting ongoing processes, using rule-based decisions based on status and property parameters to optimize packing density and process efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If objects are added to the additive manufacturing apparatus during an ongoing manufacturing process, then the manufacturing flexibility and responsiveness to new orders are improved, but the manufacturing process quality deteriorates due to interruptions and packing density reduction
Solution Approach 1:
The control device performs preliminary calculations and simulations to determine optimal positions for additional objects before they are actually added to the manufacturing apparatus. This advance planning ensures that objects can be added without interrupting the manufacturing process, as the positions are pre-determined to maintain packing density and process continuity.
Solution Approach 2:
The control device acts as an intermediary between new manufacturing orders and the ongoing manufacturing process. It receives data models of additional objects, calculates optimal positions, and integrates them into the existing manufacturing plan without causing interruptions, thereby maintaining both flexibility and quality.
2Adaptability or versatility
If the manufacturing process is interrupted to add new objects, then the manufacturing flexibility is improved, but the productivity and efficiency deteriorate due to process interruptions
Solution Approach 1:
The system enables continuous manufacturing operations by allowing new objects to be added to the apparatus without interrupting the ongoing manufacturing process. The control device calculates positions and integrates new objects in a way that maintains continuous laser scanning and material deposition, eliminating downtime and maintaining full productivity.
3Productivity
If objects are added during an ongoing manufacturing process, then the responsiveness to new orders is improved, but the packing density deteriorates due to reduced construction space utilization
Solution Approach 1:
Before adding new objects to the manufacturing apparatus, the control device performs preliminary calculations to determine optimal positions that maximize packing density. This advance planning ensures that new objects are integrated efficiently into the available construction space, maintaining high material utilization while accepting new orders.
Solution Approach 2:
The system dynamically adjusts the manufacturing plan by recalculating optimal positions for both existing and new objects. This dynamic optimization ensures that packing density is maintained even as new objects are added, adapting the construction space utilization in real-time to respond to new manufacturing orders.
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
Enhances manufacturing efficiency by reducing downtime, improving packing density, and lowering costs through automated object assignment across multiple apparatuses.
Implementation Method 1
a laser beam is moved over those positions of a layer of the build material that correspond to the object cross-section of the object to be manufactured in this layer, so that the build material is solidified at these positions
Implementation Method 2
supplying thermal energy to the build material by irradiating the same with electromagnetic radiation or particle radiation (e.g., laser sintering (SLS or DMLS) or laser melting or electron beam melting)
Implementation Method 3
supplying thermal energy to the build material by irradiating the same with electromagnetic radiation or particle radiation (e.g., laser sintering (SLS or DMLS) or laser melting or electron beam melting)
Data Source
AI summary
A computer-aided method of controlling a plurality of additive manufacturing apparatuses. The method includes receiving first computer-based data models each of which geometrically describes a first object to be manufactured, receiving status data and/or property parameters of the plurality of additive manufacturing apparatuses, to each of which at least one second computer-based data model of a second object to be manufactured has been assigned, transmitting a first computer-based data model to a target manufacturing apparatus among the plurality of additive manufacturing apparatuses for a manufacture of the first object, where the target manufacturing apparatus is selected on the basis of a rule-based automatic decision in which the received status data and/or property parameters are taken into account.