Additive Manufacturing Spatial Offset Control for Track Uniformity
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Solution Overview
Problem
Additive manufacturing processes often result in imperfections and non-uniformity in manufactured components due to variations in the shape of consolidated material tracks along their length, particularly at initiation and termination points, leading to surface roughness and inconsistencies in the outer surface of the components.
Innovation Solution
The method involves determining process parameter values and spatial offset parameter values to control the additive manufacturing system, adjusting the location and termination points of consolidated material tracks, and varying the energy delivery along the scan path to enhance uniformity and surface smoothness, using a combination of feedstock material supply and energy application to form a melt pool that is moved along the path to define consistent tracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive manufacturing processes are used with standard process parameters, then manufacturing speed and productivity can be maintained, but surface roughness and non-uniformity increase due to variations in consolidated material track shapes
Solution Approach 1:
The patent applies preliminary action by determining spatial offset parameter values before actual manufacturing. Test components are manufactured first to establish correlations between process parameters and track geometry, which are then used to pre-calculate spatial offset values that compensate for initiation and termination effects, eliminating surface roughness issues before production begins
Solution Approach 2:
The patent changes parameters by introducing spatial offset parameter values that adjust the relative positioning between adjacent consolidated material tracks. This parameter modification allows tracks to be positioned optimally to minimize surface variations caused by initiation and termination, improving surface uniformity without reducing manufacturing speed
2Manufacturing precision
If the shape of consolidated material tracks is allowed to vary with position, then manufacturing process flexibility is maintained, but imperfections and surface roughness occur at initiation and termination points
Solution Approach 1:
The patent applies local quality by determining that different portions of consolidated material tracks require different spatial offset treatments. Specifically, initiation and termination regions are identified and given special spatial offset parameter values to compensate for their inherent non-uniformity, while mid-sections use standard parameters, thus improving overall track uniformity without excessive complexity
3Productivity
If larger hatch distances are used to increase productivity, then manufacturing speed improves, but surface uniformity and quality may be compromised
Solution Approach 1:
The patent uses preliminary action to pre-determine optimal spatial offset parameter values based on the specific hatch distance being used. By establishing correlations between hatch distance and spatial offset requirements through test components, the system can maintain surface uniformity even at larger hatch distances, thus preserving both productivity and quality
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 results in more uniform and smoother surfaces of manufactured components with reduced surface roughness and improved merging of distinct regions, allowing for faster production with larger hatch distances while maintaining uniformity and quality.
Implementation Method 1
delivering, from an energy source of the additive manufacturing system and to an addition location along the scan path, an amount of energy sufficient to form a melt pool of the feedstock material at the addition location
Implementation Method 2
moving the addition location along the scan path to move the melt pool along the scan path and define a plurality of consolidated material tracks from the feedstock material
Data Source
Figure 1
Figure 2
Figure 3~4(b)
AI summary
Methods of manufacturing a manufactured component, additive manufacturing systems that perform the methods, and storage media that directs additive manufacturing systems to perform the methods. The methods include determining a process parameter value and determining a spatial offset parameter value based upon the process parameter value. The methods also include forming the manufactured component utilizing the additive manufacturing system. The forming includes supplying a feedstock material, delivering, to an addition location, an amount of energy sufficient to form a melt pool of the feedstock material, and moving the addition location along a scan path to define a plurality of consolidated material tracks from the feedstock material. Each consolidated material track extends between a corresponding initiation location and a corresponding termination location, and a location of at least one of the corresponding initiation location and the corresponding termination location is based on the spatial offset parameter value. (Fig. 2)