Additive Manufacturing Irradiation Segmentation for Efficiency
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Solution Overview
Problem
Conventional additive manufacturing methods for three-dimensional objects are inefficient due to long non-productive times and require additional space for coating units during irradiation, making the process cost-intensive and time-consuming.
Innovation Solution
The method involves subdividing the building space into segments and assigning irradiation units to these segments, allowing for overlapping or adjacent irradiation areas to minimize total irradiation time by optimizing the position and orientation of the irradiation units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a strictly serial sequence of applying a new layer and irradiating it is used, then the irradiation can be performed along constant irradiation areas, but very long non-productive times occur which reduce system efficiency
Solution Approach 1:
The building space is divided into multiple segments along the direction of extension of the building platform. Each segment is assigned to a specific irradiation unit, enabling parallel processing of different segments. This segmentation allows the system to process multiple irradiation areas simultaneously, dramatically reducing non-productive times while maintaining selective solidification quality in each segment.
Solution Approach 2:
The patent introduces dynamic adaptation of irradiation areas by adjusting the position and orientation of irradiation units based on the specific structure to be manufactured. This dynamic configuration allows optimization of irradiation paths and minimizes non-productive movement times, thereby improving overall system efficiency without compromising manufacturing precision.
2Ease of operation
If additional space is provided outside the installation space to accommodate the coating unit during irradiation, then the coating unit can be stowed away, but the system requires more space and becomes less compact
Solution Approach 1:
The coating unit is integrated within the installation space by positioning it to move along the building platform in a nested configuration. During irradiation, the coating unit repositions itself within the same installation space rather than requiring external accommodation areas. This nesting approach eliminates the need for additional external space while maintaining operational ease.
Solution Approach 2:
The patent resolves the space conflict by utilizing the third dimension (vertical movement and multi-level positioning) rather than requiring additional horizontal space. The coating unit can move vertically and reposition within the existing installation footprint, transforming a two-dimensional space problem into a three-dimensional solution that maintains system compactness.
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 non-productive times, optimizes process time for manufacturing three-dimensional objects, and allows for efficient production with consistent quality, while also eliminating the need for additional space during irradiation.
Implementation Method 1
at least two irradiation units for the locally selective solidification of the build-up material in the building plane
Data Source
AI summary
The invention relates to a method for the additive manufacturing of at least one three-dimensional object (1) by means of a system comprising a coating unit (40) and at least two irradiation units (50), the irradiation areas of which partially overlap or are adjacent to each other, wherein the irradiation areas are adapted so that a total irradiation period for selectively solidifying one or more layers of applied build-up material (30) is minimised as required. The invention further relates to a system for additive manufacturing of three-dimensional objects and a computer-readable storage medium.