Additive Layer Production via Segmented Solidification
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Solution Overview
Problem
Existing generative manufacturing methods for component production, such as selective laser melting and 3D printing, are often costly and time-consuming due to the high energy requirements and long process times associated with producing homogeneous material layers.
Innovation Solution
A method involving the application of two distinct layer components, where one component fills a surface portion of the layer plane and the other fills the remaining gaps, allowing for location-selective solidification, potentially using electrostatic application devices for efficient distribution and parallelization of process steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-energy point-based laser irradiation is used for site-selective solidification, then solidification can be achieved, but equipment cost and complexity increase
Solution Approach 1:
The patent segments the material layer into first and second layer components with different solidification properties. The first layer component is applied first, then the second layer component is applied to the same or remaining portions. This segmentation allows the second layer component to serve as a solidification trigger, eliminating the need for expensive high-energy laser equipment while achieving reliable site-selective solidification.
Solution Approach 2:
The second layer component acts as an intermediary substance that enables solidification without requiring direct high-energy irradiation. By incorporating the second layer component into the material layer, it serves as a mediator that triggers solidification through its own solidification process, thereby reducing equipment complexity and cost.
2Productivity
If continuous material layer production is used, then production efficiency improves, but processing time for solidification increases
Solution Approach 1:
The patent applies the first layer component continuously to form the base material layer, then applies the second layer component to the same or remaining portions before solidification. This preliminary application of the second layer component ensures that solidification triggers are already in place, allowing for rapid subsequent solidification and reducing overall processing time while maintaining continuous production efficiency.
Solution Approach 2:
The patent merges the application of the second layer component with the continuous production process. By applying the second layer component during the same operational sequence as the first layer component, the patent combines material deposition and solidification triggering into a unified process, eliminating separate solidification steps and reducing total processing time.
3Stability of the object's composition
If homogeneous material layers are produced, then material uniformity is achieved, but equipment cost and process complexity increase
Solution Approach 1:
The patent applies local quality by using the first layer component for the base material and the second layer component for specific portions that require solidification. This allows different regions of the material layer to have different compositions and properties, achieving the necessary homogeneity for structural integrity while using simpler equipment and reduced process complexity compared to producing entirely homogeneous layers throughout.
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 reduces equipment costs and process time by enabling efficient, location-specific solidification of material layers, achieving a defined layer thickness and uniformity while allowing for the use of different materials with varying solidification properties.
Implementation Method 1
a site-selective solidification of the material layer can be produced by means of at least one of the layer components
Data Source
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Figure 4~5
AI summary
The invention relates to a device (10) and a method comprising: generating a material layer (12) for producing a layer stack for additive manufacturing of components; wherein the generation of the material layer (12) comprises: - applying a first layer component (201); and - applying a second layer component (202, 301, 302), wherein a site-selective solidification of the material layer (12) can be achieved by means of at least one of the layer components (201, 202, 301, 302); and wherein the production of the material layer (12) further comprises at least one of the following measures of: a) applying the first layer component (201) filling at least a portion of a layer plane (E) of the material layer (12) to be produced and applying the second layer component (202, 301, 302) to the same portion, wherein at least the second layer component (202, 301, 302) is in a solid state;b) Applying the first layer component (201) without completely filling a layer plane (E) of the material layer (12) to be produced and applying the second layer component (202, 301, 302) in at least one unfilled portion (18) of the layer plane (E).;