Additive Manufacturing Section Patterning to Prevent Seam Stacking
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Solution Overview
Problem
Existing additive manufacturing processes face challenges in minimizing deformation and seam alignment issues due to thermal or chemical reaction kinetics, as pre-set repeating patterns for section patterning are not tailored to the specific article being manufactured, leading to potential vertical seam stacking.
Innovation Solution
A method and apparatus that determine patterns of discrete sections for layers of fusible material, with section boundaries optimized to avoid alignment with other layer patterns based on criteria such as thickness, geometry, mechanical properties, and proximity, using iterative or randomized approaches to minimize seam alignment and deformation, and an additive manufacturing apparatus with a controller to implement these patterns with an energy beam scanning emitter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pre-set repeating patterns are used for section patterning, then the process is simple and fast, but vertical seam stacking occurs and deformation increases
Solution Approach 1:
The patent implements dynamic section patterning where the section boundaries are adjusted layer-by-layer based on the specific geometry and characteristics of the article being manufactured. Instead of using static pre-set repeating patterns, the system dynamically determines optimal section patterns for each layer to prevent vertical seam stacking while maintaining manufacturing efficiency.
Solution Approach 2:
The patent applies different section patterning strategies to different regions of the article based on local geometric characteristics, thickness variations, and mechanical property requirements. This allows the section boundaries to be optimized for each specific region, preventing seam alignment issues in critical areas while maintaining overall manufacturing productivity.
2Manufacturing precision
If section boundaries are varied between adjacent layers, then direct seam stacking is reduced, but complex pattern determination is required
Solution Approach 1:
The patent changes key parameters such as section boundary positions, section sizes, and scanning directions between adjacent layers based on article-specific criteria. This systematic parameter variation effectively prevents vertical seam stacking while the underlying algorithm maintains manageable complexity by following established optimization rules.
Solution Approach 2:
The patent uses computational algorithms to determine optimal section patterns, effectively copying and adapting proven patterning strategies from similar geometric configurations. This approach reduces the complexity of pattern determination by leveraging existing knowledge and systematic methods rather than requiring entirely new patterns for each layer.
3Stability of the object's composition
If discrete sections are used to reduce thermal deformation, then layer deformation is minimized, but seam alignment issues persist with pre-set patterns
Solution Approach 1:
The patent divides each layer into discrete sections that are scanned separately, which helps reduce thermal deformation by limiting the heat-affected zone in each section. The key innovation is that the section boundaries are dynamically determined to ensure that seams from adjacent layers do not align vertically, thus maintaining both deformation control and seam alignment.
Solution Approach 2:
The patent introduces asymmetry in the section patterning between adjacent layers by deliberately offsetting section boundaries and varying section configurations. This asymmetric approach prevents vertical seam stacking while maintaining the benefits of discrete section scanning for thermal deformation control.
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
The solution effectively reduces seam alignment and deformation by dynamically adjusting section patterns according to article-specific criteria, enhancing the quality and integrity of the manufactured article by minimizing thermal and chemical reaction effects.
Implementation Method 1
laser additive manufacturing (using a powder as a feedstock and selectively melting the powder using a laser)
Implementation Method 2
an energy beam applied in a scanning pattern to each of the discrete sections sequentially
Data Source
AI summary
A method of making an article is disclosed involving determining a plurality of patterns of discrete sections for a plurality of layers of fusible material. According to the method, the patterns are determined having section boundaries that avoid alignment with section boundaries of other layer patterns among the plurality of patterns according to criteria specified for the article. Layers of fusible material are repeatedly fused with an energy beam applied in a scanning pattern to each of the discrete sections sequentially for each of the plurality of patterns in the plurality of layers.