Additive Manufacturing Spatial Heat Treating System
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Solution Overview
Problem
Current additive manufacturing techniques face inefficiencies in the smooth and efficient production of printed parts, particularly in achieving desired material properties and structural integrity through layer-by-layer addition, where traditional machining methods like drilling and cutting are more prevalent.
Innovation Solution
The implementation of a system and method utilizing two-dimensional energy patterning for both printing and heat treatment in additive manufacturing, which includes energy sources like lasers and electron beams, combined with beam shaping optics and patterning units to direct and control energy beams for precise material modification, allowing for the creation of complex structures and control over cooling rates to achieve desired crystalline structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional machining methods (drilling, cutting, grinding) are used to form parts, then material removal is achieved, but manufacturing efficiency and material utilization are reduced
Solution Approach 1:
The patent replaces traditional mechanical machining methods (drilling, cutting, grinding) with additive manufacturing using energy beams (laser, electron beam) to selectively melt and fuse powder material layer-by-layer, constructing parts directly from digital models without material removal
Solution Approach 2:
The patent changes the fundamental manufacturing parameter from subtractive material removal to additive material deposition, using controlled energy input to melt and fuse powder material into desired three-dimensional structures, thereby improving productivity and reducing material loss
2Productivity
If layer-by-layer addition is used in additive manufacturing, then complex structures can be created, but manufacturing smoothness and efficiency are compromised
Solution Approach 1:
The patent merges the printing process and heat treatment process into a single integrated operation, where the energy beam simultaneously deposits material and applies controlled thermal processing to achieve desired microstructures and surface properties, thereby improving both productivity and surface quality
Solution Approach 2:
The patent applies heat treatment during the printing process itself rather than as a subsequent separate operation, pre-treating the deposited material in-layer to achieve desired crystalline structures and surface smoothness before the part is complete, thereby improving manufacturing efficiency
3Manufacturing precision
If separate printing and heat treatment processes are used, then material properties can be controlled, but manufacturing time and energy consumption increase
Solution Approach 1:
The patent combines printing and heat treatment into a single integrated process where the energy beam performs both material deposition and thermal processing simultaneously, eliminating the need for separate operations and reducing manufacturing cycle time
Solution Approach 2:
The energy beam system is designed to perform multiple functions - melting and fusing powder material for deposition, and applying controlled heat treatment for microstructure development - thereby reducing the number of separate processes needed and improving manufacturing 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 enables the efficient production of complex three-dimensional structures with controlled material properties, improving manufacturing throughput and energy efficiency by allowing for simultaneous printing and heat treatment, thereby overcoming the limitations of traditional machining methods.
Implementation Method 1
an energy source configured to emit one or more energy beams
Implementation Method 2
energy sources like lasers and electron beams
Implementation Method 3
powder bed fusion using two-dimensional energy patterning to both print and heat treat
Implementation Method 4
control over cooling rates to achieve desired crystalline structures
Implementation Method 5
control over cooling rates to achieve desired crystalline structures
Data Source
AI summary
An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. The two-dimensional energy patterning system may be used to control the rate of cooling experienced by each successive additive layer. Accordingly, the system may be used to heat treat the various additive layers.