Additive Manufacturing Scan Line Time Control
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Solution Overview
Problem
Existing additive manufacturing techniques face challenges in achieving predictable and repeatable material characteristics for three-dimensional articles, as they are often dependent on the shape and size of the article being built, leading to inconsistencies in microstructure and properties.
Innovation Solution
A method involving the use of a constant energy beam with a time sink to maintain consistent scan line time across the three-dimensional article, allowing for tailored material characteristics by adjusting scan line direction, speed, and energy density, and potentially using multiple energy beam sources to control build temperature and microstructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the same melt beam current is used for the entire layer, then the energy input is uniform across the layer, but the scan line time varies causing excessive overmelt on short scan lengths and insufficient energy on long scan lengths
Solution Approach 1:
The patent applies parameter changes by adjusting the melt beam current based on scan line length. Shorter scan lines receive reduced energy input while longer scan lines receive increased energy input, maintaining consistent material characteristics and microstructure throughout the layer despite varying scan line lengths.
Solution Approach 2:
The patent implements local quality by applying different energy parameters to different regions of the powder bed. Each scan line receives customized energy input according to its specific length, ensuring that local material properties remain consistent across the entire build area.
2Manufacturing precision
If the energy and scan speed are adjusted to keep time between hatches constant, then the scan line time is consistent, but other parameters such as solidification rate and thermal gradient change affecting microstructural properties
Solution Approach 1:
The patent changes multiple parameters simultaneously - adjusting both scan speed and melt beam current based on scan line length. This coordinated parameter adjustment maintains consistent scan line time while preserving stable solidification rates and thermal gradients, thereby maintaining consistent microstructural properties.
3Stability of the object's composition
If the scan line time is extended to provide sufficient energy for long scan lines, then energy contribution is adequate, but the build time increases and productivity decreases
Solution Approach 1:
The patent applies local quality by providing extended energy input only where needed - specifically for longer scan lines. Shorter scan lines maintain their original faster processing time, while longer scan lines receive additional energy input. This localized approach ensures adequate energy contribution for proper fusion without uniformly extending the overall build time.
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 improves the control and predictability of material characteristics such as tensile strength and microstructure, ensuring consistent properties regardless of the article's shape and size, while minimizing idling time for the energy beam and maintaining optimal build temperature.
Implementation Method 1
directing an energy beam from a first energy beam source over a work table with a constant energy causing a first layer of powder to fuse in first selected locations according to a model to form a first cross section of the three-dimensional article
Implementation Method 2
locations with a shorter scan line time than a maximum scan line time is provided with a time sink before and/or after the scan line so that the scan line time plus the time sink is constant for the first cross section of the three-dimensional article
Data Source
Figure 1A(i)~1B(iii)
Figure 1C(i)~1C(iii)
Figure 2A~2B
AI summary
The invention relates to a method for forming a three-dimensional article through successive fusion of locations of a powder bed. The method comprising: providing a model of said three-dimensional article; applying a powder layer on a work table; determining a maximum scan length of an energy beam; directing said energy beam from a first energy beam source over said work table with constant energy causing said first powder layer to fuse in first selected locations according to said model to form a first cross section of said three-dimensional article, wherein locations with a shorter scan length than said maximum scan length is provided with a time sink before and/or after said scan line so that the time period between each two adjacent scan lines is constant throughout the manufacture of said three-dimensional article.