Electron Beam Blocking for Fast Power Control in Powder Bed Fusion
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Solution Overview
Problem
Additive manufacturing apparatuses using electron beams struggle with quickly controlling the power of the electron beam, which is essential for heating and fusing powder materials effectively.
Innovation Solution
The implementation of a diode electron source with a beam blocking part, which can variably block the electron beam by interference, allowing for rapid control of the electron beam power through reshaping and defocusing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a diode electron source is used instead of a triode, then the device complexity is reduced and ease of manufacture is improved, but the ability to quickly control electron beam power deteriorates due to lack of a grid for beam turning
Solution Approach 1:
A beam blocking part is introduced as an intermediary component between the diode electron source and the powder bed. This beam blocking part can rapidly intercept and block the electron beam, providing fast power control capability without requiring a complex triode grid structure. The beam blocking part acts as a mediator that enables quick beam termination while maintaining the simplicity of the diode design.
2Manufacturing precision
If the electron beam is quickly turned on and off for precise power control, then the manufacturing precision is improved, but the loss of time due to beam setup and turning deteriorates
Solution Approach 1:
The beam blocking part is pre-positioned in the electron beam path before manufacturing operations begin. This preliminary placement ensures that the beam can be immediately blocked or activated without requiring time-consuming adjustments or movements during the manufacturing process, thus reducing beam setup time while maintaining precise power control capability.
3Ease of operation
If a beam blocking part is introduced to control electron beam power, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The beam blocking part is designed as a separate, extractable component that can be independently controlled and positioned. This extraction approach allows the blocking function to be added to the system without fundamentally redesigning the entire electron source structure. The beam blocking part can be independently actuated, providing ease of operation while minimizing the complexity increase to the overall apparatus.
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 solution enables fast and precise control of the electron beam power, improving the fusing process by allowing quick adjustments at beam turning points and reducing unwanted heating effects.
Implementation Method 1
a beam blocking part for receiving energy from the electron beam source for controlling the electron beam power
Implementation Method 2
at least one lens for reshaping of the electron beam
Implementation Method 3
an electron source and a powder bed, said method comprising the step: blocking a selected cross section of said electron beam for controlling the electron beam power
Data Source
AI summary
The present invention relates to an apparatus and a method for an electron beam system for manufacturing a three-dimensional object by fusing successive layers of powder, said system having at least one lens for reshaping of said electron beam, an electron source and a powder bed, said method comprising the step: blocking a selected cross section of said electron beam for controlling the electron beam power. By interference between the electron beam and a beam blocking part a portion of the electron beam is prevented from reaching the powder bed.