Additive Manufacturing Laser Detection for Chamber Safety

Solution Overview

Problem

Existing additive manufacturing devices for three-dimensional object production using laser radiation lack active detection systems to prevent potential safety risks from secondary radiation reflecting onto process chamber delimiting elements, relying on passive reinforcement methods like increased wall thickness.

Innovation Solution

Incorporation of a detection device within the device to actively detect the penetration of laser radiation into or through process chamber delimiting elements, utilizing detection elements that can sense changes in radiation properties, electrical or thermal properties, or material removal, and communicate with a control device to mitigate risks by adjusting the laser power or shutting down the device.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If wall thickness of process chamber wall elements is increased to counter laser radiation penetration, then safety against laser radiation is improved, but device complexity and material consumption increase

Engineering Contradiction:

Improvesafety against laser radiationVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

A detection device is introduced as an intermediary component between the laser radiation source and the process chamber wall. This detection device includes sensors that detect laser radiation penetration and trigger safety measures, serving as an active intermediary protection mechanism rather than relying solely on passive wall thickness increases.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The detection device establishes a feedback loop by continuously monitoring for laser radiation penetration and communicating with the control device. When penetration is detected, the control device receives feedback and automatically reduces laser power or shuts down the device, creating a closed-loop safety system that responds dynamically to conditions.

Inventive Principle:

Principle #23Feedback

2Reliability

If detection device is added to actively monitor laser radiation penetration, then safety monitoring capability is improved, but device complexity increases

Engineering Contradiction:

Improvesafety monitoring capabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

A detection device is introduced as an intermediary component between the laser radiation source and the process chamber wall. This detection device includes sensors that detect laser radiation penetration and trigger safety measures, serving as an active intermediary protection mechanism rather than relying solely on passive wall thickness increases.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The detection device establishes a feedback loop by continuously monitoring for laser radiation penetration and communicating with the control device. When penetration is detected, the control device receives feedback and automatically reduces laser power or shuts down the device, creating a closed-loop safety system that responds dynamically to conditions.

Inventive Principle:

Principle #23Feedback

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 safety by actively monitoring and preventing laser radiation from penetrating process chamber delimiting elements, reducing the risk of accidents and improving operational security during additive manufacturing processes.

Implementation Method 1

a detection device (11), in particular a detection device which is set up for detecting penetration of laser radiation into a process chamber delimiting element that delimits the process chamber at least in sections and/or for detecting penetration of laser radiation through a process chamber delimiting element that delimits the process chamber at least in sections

Methodology Applied

Scientific EffectLaser radiation detection: Absorption (EM radiation)

Implementation Method 2

for detecting penetration of laser radiation through a process chamber delimiting element

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 3

an exposure device (6), in particular an exposure device which is set up for selective exposure of building material layers to be selectively solidified in the building plane of the device by means of laser radiation

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 4

for the selective exposure of building material layers to be selectively solidified in the building plane of the device by means of laser radiation

Methodology Applied

Scientific EffectSelective laser melting: Selective Laser Sintering

Data Source

PatentEP3321064B1Apparatus for additively manufacturing of three-dimensional objects

Publication Date: 2022.03.02 CL SCHUTZRECHTSVERW

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AI summary

Device (1) for the additive manufacturing of three-dimensional objects (2) by successive layer-by-layer selective exposure and associated successive layer-by-layer selective solidification of building material layers made of a building material (3) that can be solidified by means of laser radiation in a process chamber (10) on the device side, comprising an exposure device (5) which is configured to generate laser radiation for selective exposure and associated selective solidification of respective building material layers, and a detection device (11) which is configured to detect the penetration of laser radiation into a process chamber boundary element that at least partially delimits the process chamber (10) and/or to detect the penetration of laser radiation through a process chamber boundary element that at least partially delimits the process chamber (10).