Additive Manufacturing Layer Pauses for Surface Area Heat Control
Find Innovative SolutionsGenerate Solutions
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 build 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, and determining the length of the delay based on the surface area change to reduce build failures.
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 speed and productivity are improved, but temperature variations cause build failures such as shrinkage, uneven builds, and poor surface quality
Solution Approach 1:
The patent applies periodic action by interrupting the continuous energy beam process. The method temporarily discontinues melting and fusing between layers when surface area change exceeds a threshold, creating periodic pauses that allow heat dissipation. This prevents temperature variations while maintaining overall productivity by resuming the process after the delay.
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 failures
Solution Approach 1:
The patent implements feedback control by monitoring the surface area change between consecutive layers. When the change exceeds a predetermined threshold, the system automatically triggers a delay in the energy beam process. This feedback mechanism allows the system to adapt to geometric complexity while controlling temperature by pausing when heat accumulation becomes problematic.
3Productivity
If the energy beam processes large surface area layers continuously, then the manufacturing efficiency is improved, but the build quality deteriorates due to temperature variations
Solution Approach 1:
The patent uses periodic action by introducing controlled interruptions in the energy beam process. When large surface area layers are detected, the system pauses between layers to allow cooling, then resumes processing. This maintains manufacturing efficiency by only interrupting when necessary while preserving build quality through temperature control.
Solution Approach 2:
The patent changes the temporal parameter of the manufacturing process by introducing variable delays between layers. The delay duration is adjusted based on the surface area change threshold, effectively changing the process parameters dynamically to balance productivity and precision requirements.
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 controlling heat distribution and maintaining the build quality of the final component, enabling the creation of complex geometries with improved performance and reliability.
Implementation Method 1
an apparatus builds objects in a layer-by-layer manner by sintering or melting a powder material using an energy beam
Implementation Method 2
melting and fusing, via an energy beam of an energy source of the additive manufacturing system, material layer by layer
Implementation Method 3
the delay allows for one or more previously built layers to at least partially cool so as to eliminate and/or reduce build failures
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method (200) for additively manufacturing a component (100) includes receiving, via an additive manufacturing system (100), a geometry of the component (100) and melting and fusing, via an energy beam (122) of the additive manufacturing system (100), material layer by layer atop a build platform (118) according to the geometry so as to build up a plurality of layers that form the component (100). The method (200) also includes determining a surface area change from one of the plurality of layers to the next based on the geometry. Further, the method (200) includes temporarily discontinuing melting and fusing of the material by the energy beam (122) 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 (108).