Additive Manufacturing Control Data for Layer Heat Uniformity
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Solution Overview
Problem
Additive manufacturing processes face challenges with inhomogeneous energy absorption by the component, leading to uneven heat distribution, which can disrupt the manufacturing process, increase support volume, and slow down production, especially in the production of uniform surfaces or regular contours.
Innovation Solution
A method and device for generating control data that corrects irradiation values based on spatially resolved thermal data, identifying special areas with predetermined shape and manufacturing features, and applying different correction factors to compensate for inhomogeneities, ensuring uniform energy input across component layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If uniform irradiation is applied across all areas, then manufacturing process is simple, but inhomogeneous heat distribution occurs leading to process interruptions
Solution Approach 1:
The patent applies local quality by differentiating between special areas and non-special areas in the construction field. Special areas (such as corners, edges, or areas with specific geometric features) are identified and assigned different irradiation correction factors than non-special areas. This allows the system to address heat distribution inhomogeneities locally without complicating the entire control system, thereby improving manufacturing reliability while maintaining reasonable device complexity.
Solution Approach 2:
The patent changes the irradiation parameters (energy input, power, speed) dynamically based on the identified special areas. By adjusting these parameters locally in different regions of the construction field, the system compensates for inhomogeneous heat absorption and prevents process interruptions, thus improving reliability without requiring fundamentally more complex equipment.
2Reliability
If support volume is increased to prevent heat-related problems, then process stability improves, but production speed decreases and costs increase
Solution Approach 1:
The patent performs preliminary identification of special areas before the additive manufacturing process begins. By pre-calculating and marking areas that are prone to heat-related issues based on the digital model, the system can proactively apply appropriate irradiation correction factors during manufacturing. This prevents process interruptions without requiring excessive support structures, thereby maintaining both reliability and productivity.
3Manufacturing precision
If correction factors are applied to all areas, then heat distribution uniformity improves, but processing time increases
Solution Approach 1:
The patent applies correction factors selectively only to identified special areas rather than uniformly across the entire construction field. This localized approach achieves the necessary heat distribution uniformity in critical regions while avoiding unnecessary processing delays in areas that do not require correction, thus balancing manufacturing precision with processing time efficiency.
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
The method enhances manufacturing stability, prevents process interruptions, reduces support volume, and increases process speed, resulting in improved component quality and reduced costs.
Implementation Method 1
providing a process room sensor data set of a currently solidified component layer recorded by means of a sensor arrangement, wherein the process room sensor data set comprises at least spatially resolved thermal data
Implementation Method 2
selective solidification of building material by irradiation of the building material with at least one energy beam
Implementation Method 3
the building material is selectively solidified in a 'welding process' by spatially limited irradiation of the areas that are to be part of the component to be manufactured after production, in which the powder grains of the building material are partially or completely melted with the help of the energy introduced locally by the radiation at this point
Data Source
AI summary
The invention relates to a method for generating control data (PS) for a device (1) for additive manufacturing of a component (2) in a manufacturing process, in which building material (13), preferably comprising a metal powder, is built up layer by layer in a construction field (8) by selective solidification of building material (13) by irradiation of the building material (13) with at least one energy beam (22), the method comprising the steps:recording of a process room sensor data set (SD) with spatially resolved thermal data of a currently solidified component layer (B),providing a process room control data set (KD) with an intended shape (F) of the currently solidified component layer (B),defining a number of special areas(S) in the intended shape (F),assigning the number of special areas(S) to corresponding areas in the process room sensor data set (SD),generating a correction factor module (KK), wherein correction factors (KF) in the special areas(S) are generated according to different rules than in other areas of the intended shape (F) outside the special areas(S),correcting control data (PS) for the additive manufacturing of a subsequent component layer (B1) based on the correction factor module (KK),outputting the corrected control data (PS) to a device (1) for additive manufacturing of a component (2).The invention also relates to corresponding control data, a method for additive manufacturing, a control data generation device, a control device and a manufacturing device.