Additive Manufacturing Command Timing for Multi-Laser Build Precision
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Solution Overview
Problem
Existing additive manufacturing technologies face uncertainties in the timing of machine operations, leading to inefficiencies and inaccuracies in calculating heat input during the build process, especially when using multiple lasers, which can result in unacceptable builds due to insufficient or excessive energy input.
Innovation Solution
A method of controlling additive manufacturing apparatus by associating each command with a specific execution time, allowing for precise timing of actions and simultaneous execution of multiple subsystems, using a master clock to synchronize local clocks and incorporating time stamps for sensor data to ensure accurate energy input and position determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If sequential control system is used to execute machine operations, then ease of operation is improved, but manufacturing precision deteriorates due to timing uncertainties
Solution Approach 1:
The control system transitions from static sequential execution to dynamic time-synchronized execution. Each command is tagged with an identifier representing its execution time, allowing the system to dynamically adjust operation timing while maintaining coordinated control of multiple subsystems, thereby achieving both ease of operation and manufacturing precision
2Productivity
If multiple lasers are used to scan overlapping zones, then productivity is improved, but manufacturing precision deteriorates due to timing uncertainties between consolidations
Solution Approach 1:
The system dynamically coordinates multiple lasers by assigning time identifiers to each command, enabling precise synchronization of laser operations. This allows multiple lasers to work simultaneously on overlapping zones while maintaining accurate timing control for each consolidation event, ensuring consistent manufacturing precision across all consolidated regions
3Reliability
If safety margins are inserted in command ordering, then reliability is improved, but productivity deteriorates due to consequential inefficiencies
Solution Approach 1:
The system performs preliminary timing calculations and assigns optimal execution times to commands before execution. By pre-determining the timing of each operation and coordinating subsystem actions in advance, the system eliminates the need for conservative safety margins while maintaining reliability, thereby improving productivity through reduced idle time and more efficient command sequencing
Data Source
AI summary
A method controls an additive manufacturing apparatus, in which an object is built by consolidating material in a layer-by-layer manner. The method includes receiving commands to be executed by the additive manufacturing apparatus to cause the additive manufacturing apparatus to carry out a build of an object, wherein each command includes an identifier identifying a time during the build at which the command is to be executed, and executing each command on the additive manufacturing apparatus in accordance with the time identified by the associated identifier. Further, an apparatus and a data carrier carry out the method.