Additive Manufacturing Cooling Delays for Surface Area Build Changes
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Solution Overview
Problem
Additive manufacturing processes, such as direct metal laser sintering, face challenges with build failures due to temperature variations caused by sudden changes in surface area during the layer-by-layer building process, leading to issues like shrinkage, uneven builds, and poor surface quality.
Innovation Solution
Implementing a method where the additive manufacturing system temporarily discontinues melting and fusing between layers if the surface area change exceeds a predetermined threshold, allowing previously built layers to cool, thereby reducing build failures by controlling heat distribution and maintaining build quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the energy beam continuously melts and fuses material layer by layer without interruption, then the manufacturing productivity is improved, but temperature variations cause build failures such as shrinkage and uneven builds
Solution Approach 1:
The patent applies periodic action by temporarily discontinuing the energy beam between layers when surface area change exceeds a threshold. This periodic interruption allows previously built layers to cool and reduces temperature variations, preventing build failures while maintaining overall manufacturing efficiency through selective rather than continuous pausing.
2Shape
If the surface area of layers increases significantly, then the component geometry complexity is improved, but the heat required to build the layer increases causing build quality deterioration
Solution Approach 1:
The patent changes the process parameter of energy beam continuity based on surface area change thresholds. When the surface area increase exceeds a predetermined threshold, the system adjusts by pausing the energy beam, thereby controlling heat input and preventing build quality deterioration while still manufacturing complex geometries.
3Speed
If the energy beam processes large surface area layers continuously, then the manufacturing speed is improved, but temperature control deteriorates leading to shrinkage and uneven builds
Solution Approach 1:
The patent implements feedback control by monitoring surface area changes between layers and adjusting energy beam continuity accordingly. When surface area change exceeds a threshold, the system automatically pauses the energy beam to allow cooling, thereby maintaining temperature control while minimizing interruptions to manufacturing speed.
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 effectively reduces build failures by allowing layers to cool, resulting in improved surface quality and reduced shrinkage, ensuring the integrity and reliability of the final component.
Implementation Method 1
an energy beam of an energy source of the additive manufacturing system melts and fuses material layer by layer
Implementation Method 2
the delay allows for one or more previously built layers to at least partially cool
Data Source
AI summary
A method for additively manufacturing a component includes receiving, via an additive manufacturing system, a geometry of the component and melting and fusing, via an energy beam of the additive manufacturing system, material layer by layer atop a build platform according to the geometry so as to build up a plurality of layers that form the component. The method also includes determining a surface area change from one of the plurality of layers to the next based on the geometry. Further, the method includes temporarily discontinuing melting and fusing of the material by the energy beam between building of one or more of the plurality of layers so as to provide a delay after building one or more of the plurality of layers when the surface area change is above a predetermined threshold. As such, the delay allows for one or more previously built layers to at least partially cool so as to eliminate and/or reduce build failures from occurring in the final component.