Additive Manufacturing Light Beam Intensity Distribution
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Solution Overview
Problem
In additive manufacturing using the powder bed method, there is a concern that the rapid melting of metal powder by an energy beam can lead to internal defects such as cavities and surface spatters, which degrade the quality of the fabricated object.
Innovation Solution
The use of a light beam with a high-order mode intensity distribution, specifically the second order and higher order mode or a top hat shape, is employed to irradiate the powder bed, which helps in suppressing internal defects and improving surface roughness by effectively melting and solidifying the metal powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional light beam (Gaussian distribution, TEM00 mode) is used to irradiate the powder bed, then the melting process is efficient and productivity is high, but internal defects such as cavities and surface spatters are generated, deteriorating manufacturing precision
Solution Approach 1:
The patent changes the intensity distribution parameter of the light beam from Gaussian (TEM00 mode) to high-order mode (TEM10, TEM20, etc.) or top-hat shape. This parameter change redistributes the energy density across the beam cross-section, reducing peak intensity while maintaining total energy input, thereby suppressing internal defects and spatters while preserving melting efficiency
Solution Approach 2:
Instead of concentrating energy at the beam center (conventional approach), the patent inverts the intensity distribution to concentrate energy at the periphery or distribute it uniformly (high-order mode or top-hat shape). This inversion reduces the harmful peak intensity at the center that causes cavities and spatters, while still achieving efficient melting through redistributed energy
2Productivity
If the peak intensity of the light beam is high to ensure sufficient melting, then productivity is improved, but internal defects and surface spatters are generated, reducing manufacturing precision
Solution Approach 1:
The patent modifies the intensity distribution parameter of the light beam from concentrated Gaussian to distributed high-order mode or top-hat shape. This changes how total energy is spatially distributed, maintaining high melting rate through sufficient total energy while reducing peak intensity to prevent defects and spatters
Solution Approach 2:
The patent applies different intensity characteristics to different regions of the beam cross-section. High-order modes or top-hat distributions provide uniform or periphery-concentrated energy rather than center-concentrated energy, creating locally optimized heating that prevents spatters and cavities while maintaining overall melting efficiency
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 the peak intensity of the light beam, allowing for more effective heating of the weld pool, thereby improving the quality of the fabricated object by minimizing internal defects and surface spatters, while maintaining a sufficient filling rate.
Implementation Method 1
In a region irradiated with the energy beam, the metal powder is rapidly melted
Implementation Method 2
irradiating the raw material powder that forms the powder bed with a light beam having intensity distribution of a high-order mode
Data Source
AI summary
An additive manufacturing method includes: forming a powder bed by supplying a raw material powder; and irradiating the raw material powder that forms the powder bed with a light beam having an intensity distribution of a second or higher order mode or of a top hat shape.