Additive Manufacturing Layerwise Microstructure Control
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Solution Overview
Problem
Existing additive manufacturing methods lack the capability to customize structural properties, particularly mechanical properties, of three-dimensional objects by allowing for individual customization of each layer's properties during the build process.
Innovation Solution
A method utilizing multiple process parameter sets for successive layerwise selective irradiation and consolidation of build materials with energy beams, allowing for customizable microstructures and grain structures by adjusting energy input and beam parameters, enabling tailored mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single process parameter set is used during additive manufacturing, then the manufacturing process is simple and easy to control, but the structural properties and mechanical properties of the three-dimensional object cannot be customized or tailored
Solution Approach 1:
The patent segments the manufacturing process by dividing it into multiple process parameter sets, each corresponding to different layers or regions of the build material. This allows different structural properties to be customized for different parts of the final object, resolving the contradiction between adaptability and complexity by organizing complexity in a structured, manageable way
Solution Approach 2:
The patent implements dynamic adjustment of process parameters during the additive manufacturing process. The control unit dynamically selects and switches between different process parameter sets based on the specific layer or region being manufactured, enabling real-time customization of structural properties while maintaining systematic control over the increased complexity
2Strength
If multiple process parameter sets are used to customize structural properties, then the mechanical properties can be tailored, but the process control and parameter management become more complex
Solution Approach 1:
The patent incorporates feedback mechanisms where the control unit monitors the manufacturing process and adjusts process parameters accordingly. This feedback loop ensures that the correct process parameter set is applied to each layer or region, maintaining manufacturing precision even when using multiple parameter sets to achieve customized mechanical properties
Solution Approach 2:
The patent systematically changes process parameters (such as energy beam power, scanning speed, hatching distance) across different process parameter sets. By carefully managing these parameter changes and linking them to specific layers or regions through the control unit, the patent achieves customized mechanical properties while maintaining precision through structured parameter management
3Adaptability or versatility
If individual layer customization is implemented, then each layer can have optimized structural properties, but the data processing and control requirements increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-defining multiple process parameter sets before the actual manufacturing process begins. Each process parameter set is prepared and stored in advance, associated with specific layers or regions. This preliminary preparation reduces the computational burden during manufacturing and enables the control unit to simply retrieve and apply the appropriate pre-defined parameters, thus maintaining automation while supporting individual layer customization
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
Enables the creation of three-dimensional objects with customizable mechanical properties by generating specific microstructures and grain structures, improving mechanical performance through varied energy inputs and beam parameters, reducing crack formation and enhancing structural integrity.
Implementation Method 1
selective laser melting methods
Implementation Method 2
selective electron beam melting methods
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
Method for additively manufacturing at least one three-dimensional object (2) by means of successive layerwise selective irradiation and consolidation of layers (3) of build material (4) which can be consolidated by means of at least one energy beam (5), comprising the steps of: - providing a plurality of process parameter sets (PPS1 - PPSn) each comprising a plurality of process parameters (PP1 - PPn) allowing for a selective consolidation of a layer (3) of build material (4), whereby each process parameter set (PPS1 - PPSn) results in specific properties of the microstructure of an area of the respective layer (3) of build material (4) which was selectively irradiated and consolidated on basis of the respective process parameter set (PPS1 - PPSn); - using at least two different process parameter sets (PPS1 - PPSn) of the plurality of process parameter sets (PPS1 - PPSn) for additively manufacturing at least one three-dimensional object (2) by means by means of the successive layerwise selective irradiation and consolidation of layers (3) of build material (4) which can be consolidated by means of at least one energy beam (5).