Additive Manufacturing Irradiation Control Model

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Solution Overview

Problem

Current additive manufacturing systems face challenges in controlling irradiation parameters, such as energy beam intensity and scanning vectors, which affect the melting and sintering behavior of powder beds, leading to inconsistencies in the quality and uniformity of additively manufactured objects.

Innovation Solution

The implementation of an irradiation control model that determines optimal irradiation settings based on power density factors and irradiation vector factors, allowing for precise control of energy beam parameters like beam power, spot size, and scanning velocity to influence melting and sintering behavior.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If irradiation parameters (beam power, spot size, scanning velocity) are adjusted to control melting and sintering behavior, then manufacturing precision and quality consistency are improved, but device complexity and control difficulty increase

Engineering Contradiction:

Improvequality consistencyVSAvoidcontrol difficulty

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies parameter changes by dynamically adjusting irradiation parameters (beam power, spot size, scanning velocity) based on calculated irradiation settings. The system modifies these parameters in response to detected conditions to maintain optimal melting and sintering behavior, thereby improving quality consistency while managing control complexity through systematic parameter adjustment.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent implements feedback by using detected conditions (such as melt pool characteristics, powder bed state, or beam position) to calculate and adjust irradiation settings. This closed-loop control allows the system to automatically compensate for variations and maintain consistent manufacturing quality without requiring overly complex manual intervention.

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If irradiation parameters are controlled in real-time to improve quality, then manufacturing precision improves, but processing time increases

Engineering Contradiction:

ImprovequalityVSAvoidprocessing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent applies preliminary action by calculating optimal irradiation settings before actual irradiation occurs. The system pre-determines beam power, spot size, and scanning velocity based on detected conditions and stored reference data, allowing for efficient real-time control without time-consuming calculations during the manufacturing process itself.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces complex real-time mechanical control adjustments with computational methods. Instead of physically adjusting components during irradiation, the system uses calculated irradiation settings and detected conditions to automatically control parameters through software-based control algorithms, reducing processing time while maintaining precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enhances the controllability and repeatability of the additive manufacturing process, improving the quality and reducing defects in the manufactured objects by adjusting irradiation parameters in real-time or prior to manufacturing.

Implementation Method 1

The energy beam causes the selectively irradiated portions of the powder bed and/or underlying layers of an object being additively manufactured to melt

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

The energy beam causes the selectively irradiated portions of the powder bed and/or underlying layers of an object being additively manufactured to melt and/or sinter

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 3

an energy beam system configured to selectively scan an energy beam across a build plane to irradiate sequential layers of a powder bed

Methodology Applied

Scientific EffectThermal Radiation: Thermal Radiation

Data Source

PatentEP3970886A1Controlling irradiation parameters of an additive manufacturing machine

Publication Date: 2022.03.23 GENERAL ELECTRIC CO

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Figure 2A~3B
Figure 4A~4B

AI summary

A method of additively manufacturing three-dimensional objects (114), and/or a method of controlling one or more irradiation parameters (705) of the energy beam system (134), may include determining an irradiation setting (710) using an irradiation control model (700) and outputting an irradiation control command (704) to an energy beam system (134) based at least in part on the irradiation setting (710). The irradiation control model (700) may be configured to determine the irradiation setting (710) based at least in part on a power density factor (714) and/or an irradiation vector factor (716). The irradiation control command (704) may be configured to change one or more irradiation parameters (705) for additively manufacturing a three-dimensional object (114). An additive manufacturing system (100) may include an energy beam system (134) and a control system (104) that includes an irradiation controller (600). The irradiation controller (600) may include a control module (628) configured to perform such a method.