Additive Manufacturing Timing Control for Multi-Laser Build Precision
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Solution Overview
Problem
Existing selective laser melting apparatus face uncertainties in timing, leading to inefficiencies and inaccuracies in energy input during the additive manufacturing process, particularly when using multiple lasers, which complicates the calculation of heat in the workpiece and results in suboptimal build quality.
Innovation Solution
A method where commands for additive manufacturing apparatus are executed with precise timing identifiers, allowing for accurate calculations and simultaneous actions, such as scanning and wiper movement, to ensure consistent energy input and improved build processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If sequential control system is used to execute machine operations, then the machine can operate with simple control logic, but timing uncertainty increases and manufacturing precision deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-planning the entire build process before manufacturing begins. The build planner generates a comprehensive plan that includes timing identifiers for all commands, laser parameters, and process steps in advance. This allows the system to execute commands with precise timing without requiring complex real-time control, as the timing decisions are made beforehand when full system state information is available.
2Productivity
If multiple lasers are used to scan overlapping zones, then productivity increases, but timing coordination becomes more complex and manufacturing precision deteriorates
Solution Approach 1:
The build planner pre-calculates the timing identifiers for all multiple lasers before manufacturing begins. It determines the exact timing for each laser to scan overlapping zones, ensuring that adjacent regions are consolidated at precisely controlled intervals. This preliminary planning allows multiple lasers to operate simultaneously with high productivity while maintaining accurate energy input, as the timing coordination is resolved in advance rather than requiring complex real-time synchronization.
3Reliability
If safety margins are inserted in command ordering, then collision avoidance is ensured, but productivity decreases
Solution Approach 1:
The build planner pre-calculates safe timing identifiers that inherently account for collision avoidance requirements. By planning the entire build process in advance with knowledge of all machine states and constraints, the system can insert precise timing delays and coordinate movements to prevent collisions without requiring excessive safety margins. This eliminates the need for conservative time buffers that would reduce productivity, as the timing is optimized rather than merely safe.
4Manufacturing precision
If rules are implemented to ensure adjacent areas are not consolidated within a specified time threshold, then build quality is maintained, but scanning process flexibility is reduced and productivity decreases
Solution Approach 1:
The build planner pre-calculates timing identifiers that precisely control when adjacent regions are consolidated, maintaining the required time thresholds for heat dissipation while optimizing the scanning process. By planning ahead, the system can determine the minimum safe intervals between consolidating adjacent areas and schedule laser operations accordingly, rather than applying conservative rules that would unnecessarily slow down the process. This maintains build quality while maximizing scanning 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 precise control over the additive manufacturing process, reducing uncertainties and inefficiencies, allowing for accurate energy input and improved build quality by predetermining the timing of actions and synchronizing clocks within the system.
Implementation Method 1
a laser beam is scanned across portions of the powder layer that correspond to a cross-section (slice) of the workpiece being constructed. The laser beam melts or sinters the powder to form a solidified layer.
Data Source
AI summary
A method controls an additive manufacturing apparatus, in which an object is built by consolidating material in a layer-by-layer manner. The method includes receiving commands to be executed by the additive manufacturing apparatus to cause the additive manufacturing apparatus to carry out a build of an object, wherein each command includes an identifier identifying a time during the build at which the command is to be executed, and executing each command on the additive manufacturing apparatus in accordance with the time identified by the associated identifier. Further, an apparatus and a data carrier carry out the method.