Additive Manufacturing Segmentation for Non-Productive Time Reduction

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Solution Overview

Problem

Conventional additive manufacturing processes for three-dimensional objects are inefficient due to large non-productive times and require additional space for the coating unit during irradiation, making the process costly and time-consuming.

Innovation Solution

A method and system that subdivides the building space into segments, allowing for parallel application of build-up material and selective solidification using multiple irradiation units, enabling the coating unit to move efficiently and be parked in solidified segments, reducing non-productive time and space requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a strictly serial sequence of applying build-up material and irradiating it is used, then the system is simple to operate, but non-productive time increases significantly

Engineering Contradiction:

Improveoperation simplicityVSAvoidnon-productive time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The building space is divided into multiple segments along the direction of extension of the building platform. Each segment can be selectively solidified independently by associated irradiation units. This allows parallel processing where the coating unit applies material to one segment while irradiation units simultaneously solidify previous segments, eliminating idle time and maintaining operational simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system enables continuous operation by ensuring that while the coating unit is applying build-up material to the current segment, irradiation units are simultaneously solidifying previous segments. This overlapping of operations eliminates non-productive waiting time, making the useful action continuous rather than serial.

Inventive Principle:

Principle #20Continuity of useful action

2Ease of operation

If additional space is provided to accommodate the coating unit during irradiation, then the coating unit can be properly positioned, but the system footprint increases

Engineering Contradiction:

Improvecoating unit positioningVSAvoidsystem footprint

Core Design Contradiction:

Ease of operationVSArea of stationary object

Solution Approach 1:

By dividing the building space into multiple segments, the coating unit only needs to position itself over the current active segment during irradiation of previous segments. This eliminates the need for large additional space to accommodate the coating unit throughout the entire irradiation process, reducing the system footprint while maintaining proper positioning capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The building platform extends in the direction of extension, allowing segments to be arranged linearly. The coating unit moves along this dimension to service different segments, enabling compact positioning within the building space rather than requiring additional perpendicular space.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Productivity

If multiple irradiation units are used for parallel solidification, then productivity increases, but device complexity increases

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The building space is divided into multiple segments, with each segment associated with its own irradiation unit. This segmentation allows parallel solidification operations across different segments, significantly increasing productivity. The modular nature of segment-irradiation unit pairing makes the complexity manageable and scalable.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each irradiation unit is associated with a specific segment and performs the same solidification function for that segment. This multi-functional approach where identical units serve different segments allows parallel processing and increased productivity while using standardized components, which helps manage system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 optimizes the manufacturing process by minimizing non-productive time and space requirements, allowing for the efficient and cost-effective production of three-dimensional objects with consistent quality.

Implementation Method 1

at least a first irradiation unit and a second irradiation unit for the locally selective solidification of the build-up material in the building plane

Methodology Applied

Scientific EffectSelective solidification: Phase Change

Implementation Method 2

at least one coating unit for the layer-by-layer application of the build-up material in a building plane which is provided parallel to the building platform

Methodology Applied

Scientific EffectLayer-by-layer application: Deposition (physical)

Data Source

PatentUS12179430B2Process for additive manufacturing and system

Publication Date: 2024.12.31 AMCM GMBH

AI summary

The invention relates to a method for additively manufacturing at least one three-dimensional object (1) by means of a system, wherein a coating unit (40) is stopped in a segment (A; B; C; D) and/or one of its sub-segments (A1; A2; B1; B2; C1; C2; D1; D2) as a parking segment. Furthermore, the invention relates to a system for additive manufacturing of three-dimensional objects and a computer-readable storage medium.