Additive Manufacturing Part Marking Without Scan Path Disturbance
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Solution Overview
Problem
Existing additive manufacturing (AM) processes face challenges in marking components with unique serial numbers without altering the base geometry or introducing inconsistencies in scan paths, particularly when updating build plates with new markings.
Innovation Solution
A method involving converting encoded component and serialization files to text-based toolpath files, combining them with part marking geometries, and generating a combined print input file that overlays part markings onto component geometries without disturbing the component scan path, using a graphical user interface for operator input and selective laser melting (SLM).
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If part marking geometries are overlaid onto component geometries by converting to text-based toolpath files, then flexibility in updating markings is improved, but the complexity of file processing increases
Solution Approach 1:
The patent segments the marking process into separate serialization files that can be independently created and updated. Each marking is stored as a separate text-based toolpath file, allowing individual markings to be modified without affecting the component geometry or other markings. This segmentation enables flexible updates while maintaining a manageable file structure.
Solution Approach 2:
The patent performs preliminary conversion of marking geometries into text-based toolpath files before the actual additive manufacturing process. By pre-processing the marking data into a standardized format with defined character positions and values, the system eliminates the need for complex real-time processing during manufacturing, thus reducing operational complexity while maintaining flexibility.
2Manufacturing precision
If serialization files are created with predefined character positions and values, then manufacturing precision of markings is improved, but the time required to prepare marking data increases
Solution Approach 1:
The patent applies preliminary action by pre-defining character positions and values in serialization files before the manufacturing process. This pre-preparation ensures that markings are precisely positioned and formatted according to specifications, eliminating the need for adjustments during manufacturing and reducing overall preparation time through automated file generation.
Solution Approach 2:
The patent utilizes parameter changes by allowing flexible definition of character positions, values, and formatting parameters in the text-based toolpath files. These parameters can be easily modified without changing the underlying marking geometry, enabling precise control over marking appearance and position while streamlining the preparation process through parameter-based customization.
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
Ensures consistent part geometry and flexibility in marking components by maintaining the component scan path integrity while allowing for efficient and flexible application of unique serial numbers or markings, reducing processing time and enhancing operational efficiency.
Implementation Method 1
In metal powder additive manufacturing techniques, such as selective laser melting (SLM) and direct metal laser melting (DMLM), metal powder layers are sequentially melted together to form the object.
Implementation Method 2
The melting may be performed by, for example, a high-powered melting beam, such as a 100 Watt ytterbium laser, to fully weld (melt) the metal powder to form a solid metal.
Data Source
AI summary
A method for additive manufacturing an object is disclosed. The method includes converting an encoded file for a set of components to a text-based component toolpath file; creating and encoding a set of serialization (SN) files for characters in a part marking geometry; and converting encoded SN files to a set of text-based SN toolpath files. The method then generates a combined print file from the component toolpath file and the SN toolpath files to include both component and SN scan paths, wherein generating includes combining location and part marking details from a part SN location script with SN geometries from the SN toolpath files to create a modified SN toolpath file for a part marking.