Additive Manufacturing Layer Segmentation for Speed and Detail
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In additive manufacturing, particularly in laser sintering, there is a conflict between minimizing production time and achieving high detail accuracy, especially for complex components with inclined surfaces, as large laser beam focuses reduce detail quality and long layer thicknesses lead to imperfect surface realization.
Innovation Solution
The method involves decomposing the CAD model into critical and non-critical areas based on surface geometry and mechanical workability, applying varying exposure parameters for solidification, allowing for precise detail in critical areas while reducing processing time in non-critical regions by adjusting laser beam focus and power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large laser beam focus is selected for irradiation to solidify the build material in laser sintering, then the build process is shortened, but the achievable level of detail in the manufactured object is reduced
Solution Approach 1:
The patent segments the object into critical and non-critical areas based on geometric complexity and surface orientation. Different laser parameters are applied to each segment: small focus diameter and low power for critical areas requiring high detail, and large focus diameter and high power for non-critical areas where speed is prioritized. This segmentation resolves the contradiction by allowing simultaneous optimization of both speed and precision in different regions.
Solution Approach 2:
The patent implements local quality by assigning different laser exposure parameters to different spatial regions of the object. Critical areas with complex geometry or inclined surfaces receive focused, low-power irradiation to preserve detail, while non-critical flat areas receive diffuse, high-power irradiation to accelerate building. This local differentiation eliminates the need to choose between overall speed or overall precision.
2Productivity
If a large layer thickness is chosen in the layer-by-layer process, then the total number of layers decreases and build time is reduced, but the level of detail is reduced and inclined surfaces become less perfect
Solution Approach 1:
The patent segments the layer application process by thickness and location. Thin layers are applied only to critical areas requiring high surface quality, while thick layers are applied to non-critical areas where speed is essential. This spatial segmentation of layer thickness resolves the contradiction between build time and surface quality by applying the appropriate thickness to each region.
Solution Approach 2:
The patent implements local quality in layer thickness by varying the applied layer thickness across different spatial regions. Critical areas receive thin layers to ensure perfect surface realization, while non-critical areas receive thick layers to minimize the number of layers and build time. This local differentiation allows the system to achieve both fast building and high surface quality where needed.
3Manufacturing precision
If the surface areas of an object are hardened using a small-diameter laser beam while the interior is hardened using a large-diameter laser beam, then detail accuracy is improved, but for complex components with intricately designed surfaces, the extensive boundary line per object cross-section leads to long-lasting hardening of the contour line per layer
Solution Approach 1:
The patent segments the object into critical and non-critical areas, applying small-diameter laser beams only to critical areas with complex geometry rather than to all contour lines. This selective segmentation reduces the total length of high-precision hardening required, thereby reducing the time penalty while maintaining detail accuracy where it matters most.
Solution Approach 2:
The patent implements local quality by applying different laser beam diameters to different spatial regions based on geometric complexity. Small-diameter beams are used locally in critical areas requiring high detail, while large-diameter beams are used in non-critical areas. This local differentiation maintains detail accuracy in necessary regions while significantly reducing overall hardening time by avoiding excessive precision work in non-critical regions.
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 enables a compromise between production time and detail accuracy, ensuring high precision in critical areas while reducing overall construction time without compromising the quality of finished components.
Implementation Method 1
A laser 7 serves as the source of the electromagnetic radiation. The laser beam 8 generated by the laser 7 is directed into the process chamber 100
Implementation Method 2
the build material is solidified by electromagnetic radiation or energetic particle radiation
Implementation Method 3
after the application of a layer of building material of a predetermined thickness, only the portion of the layer corresponding to the surface of the object is hardened
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a method for layered production of a three-dimensional object, wherein a powdery or fluid building material, which can be solidified by the effects of electromagnetic or particle radiation, is applied in layers having a layer thickness d, and the locations in each layer which correspond to a cross-section of the object allocated to said layer are solidified by means of electromagnetic or particle radiation. According to the invention, each cross-section consists of a contour region and an inner region and the method comprises the following sub-step: in a sequence of N successive cross-sections, wherein N is a whole number greater than 1, a partial region is defined in every cross-section as a critical region and the rest of the cross-section is defined as a non-critical region, a number of N layers are applied successively, without solidification of the non-critical regions. The non-critical regions of all N layers are not solidified in all N layers until after application of the Nth layer.