Additive Manufacturing Preheating Beam Coupling
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Solution Overview
Problem
Existing 3D printing methods, such as selective laser melting (SLM) and selective laser sintering (SLS), face challenges in efficiently and accurately controlling the heating of building materials, leading to complex laser beam guidance, thermal stresses, and reduced dimensional accuracy due to uneven heating and thermal expansion.
Innovation Solution
A method where a heating jet synchronously surrounds or precedes the main jet along the solidification track, allowing for localized preheating only where necessary, reducing thermal gradients and mechanical stresses, and using a device with a beam coupler to combine heating and main beams for simultaneous guidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the entire building material in the building chamber is preheated, then the building material temperature is uniformly elevated, but the heating process becomes time-consuming and energy-intensive
Solution Approach 1:
The patent applies local preheating by directing a heating laser beam only to the specific area where the main processing laser will subsequently act. This localized approach elevates the temperature precisely where needed without heating the entire building chamber, thereby reducing preheating time and energy consumption while maintaining effective temperature elevation for the building material
2Temperature
If the building material is preheated locally to avoid melting, then the melting point is not exceeded, but complex laser guidance with meandering movements is required which complicates control and delays the process
Solution Approach 1:
The patent merges the preheating laser beam with the main processing laser beam by guiding both beams through the same optical path and scanner system. This combination allows both heating and processing functions to be performed simultaneously along the same trajectory without requiring separate complex guidance paths, thereby simplifying the control system and eliminating the need for meandering laser movements
3Stability of the object's composition
If uniform preheating is applied across the building material, then thermal expansion occurs uniformly, but thermal gradients and mechanical stresses still develop during subsequent localized heating
Solution Approach 1:
The patent applies preliminary localized heating to the specific area where the main processing laser will act. This preliminary action elevates the temperature in advance of the main processing step, creating a preheated zone that reduces thermal gradients during subsequent processing. By preheating only the target area rather than the entire building material, the system maintains thermal stability locally while avoiding the development of harmful thermal stresses
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 dimensional accuracy, reduces thermal stresses, avoids gas pores and embrittlement, and simplifies the control of scanner elements, enabling more efficient and precise additive manufacturing.
Implementation Method 1
heating or pre-heating, i. e. for warming up or warming up the building material (below its solidification temperature)... by the action of radiant energy
Implementation Method 2
a focused beam from a suitable beam source hits the areas of the layer of building material to be hardened and hardens these areas... in particular sintered or sintered, melts or melts through
Implementation Method 3
selective laser melting (SLM)... a certain energy input, particularly in the case of SLM or SLS methods, brings the building material above a solidification point, in particular a melting point. A melt pool that forms
Implementation Method 4
beam coupler device (16)... with both beams, which have separate tasks or functions, can be guided simultaneously via one and the same scanner mirror
Data Source
Figure 1~2
Figure 3~3a
Figure 4~8
AI summary
Method for the additive manufacturing of a three-dimensional object (6) by successive layer-by-layer selective solidification of layers of a building material (9) with at least one energy beam, wherein the successive layer-by-layer selective solidification of the building material (9) is carried out based on a data set describing the additively manufactured three-dimensional object (6), wherein areas of the building material intended for sintering and/or melting or perforation are heated in a temperature range below the solidification temperature of the building material (9), wherein the heating of the building material area(s) is carried out by at least one heating beam (17) which either partially surrounds or precedes or follows at least one main beam (18) used for melting, perforation or perforation, wherein the main beam (18) and the heating beam (17) are guided synchronously over the surface of the building material (9).