Additive Manufacturing Energy Configuration for Defect Reduction
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Solution Overview
Problem
Existing additive manufacturing systems face challenges in reliably producing high-quality objects due to variations in energy sources and environmental conditions, leading to defects like 'elephant skin' and 'thermal bleed', and require individual configuration for different objects and purposes.
Innovation Solution
The system configures an appropriate energy level for the energy source by forming two test objects with different energy configurations and selecting the configuration that results in higher part quality, allowing for improved object quality and reduced defect frequency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed energy configuration is used in additive manufacturing systems, then the system operation is simple, but manufacturing precision deteriorates due to variations in energy sources and environmental conditions
Solution Approach 1:
The system dynamically adjusts energy source parameters (power level, exposure time, wavelength) based on detected environmental conditions and object characteristics. This allows the same additive manufacturing system to optimize for different materials, object geometries, and environmental conditions, resolving the contradiction between maintaining simple operation and achieving high manufacturing precision across varying conditions.
Solution Approach 2:
The patent implements dynamic configuration of the energy source during the manufacturing process, allowing real-time adjustments to energy parameters based on feedback from sensors monitoring temperature, material state, and environmental conditions. This dynamic adaptation enables consistent manufacturing precision without requiring complex pre-configurations for each scenario.
2Manufacturing precision
If individual configuration is performed for different objects, then manufacturing precision improves, but productivity deteriorates due to repeated configuration processes
Solution Approach 1:
The system implements a universal configuration framework that automatically adapts to different object types, materials, and environmental conditions through sensor-based detection and algorithmic determination. This single multi-functional system replaces the need for multiple pre-configured systems, maintaining high manufacturing precision across diverse objects while improving productivity by eliminating manual reconfiguration for each new object.
Solution Approach 2:
The additive manufacturing system performs self-configuration by automatically detecting object characteristics and environmental conditions, then determining appropriate energy source parameters without external intervention. This self-service capability eliminates the time-consuming manual configuration process for each object while maintaining optimal manufacturing precision, directly resolving the productivity-precision contradiction.
3Manufacturing precision
If energy level is increased to improve fusing quality, then manufacturing precision improves, but loss of energy increases
Solution Approach 1:
The system optimizes the combination of energy parameters (power, time, wavelength) rather than simply increasing power. By adjusting multiple parameters in combination, the system achieves high fusing quality at lower energy consumption levels, resolving the contradiction between manufacturing precision and energy loss.
Solution Approach 2:
The system applies energy in controlled periodic pulses rather than continuous high-power exposure, allowing heat distribution and material response time between pulses. This periodic application achieves effective fusing with reduced total energy input compared to sustained high-power exposure, addressing the energy consumption-precision trade-off.
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 method enables more efficient and reliable production of objects by determining the optimal energy configuration for the additive manufacturing system, reducing defects and improving the quality of manufactured parts.
Implementation Method 1
Energy, for example thermal energy, is applied to the layer from an energy source of the additive manufacturing system. This causes build material on which the fusing agent has been applied to heat up above the melting temperature of the build material and to melt, coalesce and solidify.
Implementation Method 2
This causes build material on which the fusing agent has been applied to heat up above the melting temperature of the build material and to melt, coalesce and solidify.
Implementation Method 3
The fusing agent acts as an energy absorbing agent that causes build material on which it has been deposited to absorb more energy (e.g. from the energy source) than build material on which no fusing agent is deposited.
Implementation Method 4
The fusing agent acts as an energy absorbing agent that causes build material on which it has been deposited to absorb more energy (e.g. from the energy source) than build material on which no fusing agent is deposited.
Implementation Method 5
a detailing agent may be applied to reduce fusing at an object boundary to produce a part with sharp and smooth edges
Data Source
AI summary
A method of configuring an additive manufacturing system. The method comprises configuring the additive manufacturing system with a first value of an operation parameter associated with the additive manufacturing system and, with the additive manufacturing system configured with the first value of the operation parameter, forming, in a build chamber, a first object The additive manufacturing system is subsequently configured with a second value of the operation parameter and, with the additive manufacturing system configured with the second value of the operation parameter, a second object is formed in the build chamber, subsequently to forming the first object. The method further includes receiving a signal indicative of which of the first value or the second value the operation parameter is to be configured with for subsequent operation of the additive manufacturing system.