Energy Beam Build Control for Area-Specific Dimensional Consistency
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Solution Overview
Problem
Existing build systems face challenges in forming consistent build objects due to variations in the build process conditions across different areas of the target object.
Innovation Solution
The build system incorporates a change apparatus to adjust the relative position between the energy beam and the target object, allowing for differentiated build process conditions between a first area set multiple times and a second area set fewer times, or between different timings, ensuring consistent object formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the irradiation area is set multiple times at the same area, then the build object formation is enhanced, but the variation in height and size increases
Solution Approach 1:
The patent applies local quality by differentiating build process conditions between different areas of the target object. Specifically, it identifies a first area where the irradiation area is set multiple times and a second area where it is set fewer times, then applies different build conditions to each area to compensate for the cumulative effect of multiple irradiations, thereby reducing height and size variations
Solution Approach 2:
The patent changes build process parameters based on the number of times the irradiation area is set at each location. By monitoring irradiation frequency and adjusting build conditions accordingly, the system compensates for areas that receive multiple irradiations, preventing excessive material accumulation and maintaining dimensional consistency
2Ease of manufacture
If the build process conditions are uniform across all areas, then the process is simple, but the build object shows variations in height and size
Solution Approach 1:
The patent transforms the static, uniform build process into a dynamic one where build conditions are automatically adjusted based on real-time irradiation history. The system monitors how many times the irradiation area has been set at each location and dynamically modifies build parameters, creating an adaptive process that maintains precision without requiring manual intervention
Solution Approach 2:
The patent implements feedback control by monitoring the number of times the irradiation area is set at each location and using this information to adjust subsequent build conditions. This feedback mechanism ensures that areas receiving multiple irradiations receive compensatory adjustments, maintaining dimensional consistency while keeping the overall process automated and relatively simple
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 formation of build objects with reduced variations in height and size, improving the accuracy and consistency of the build process across different areas and timings.
Implementation Method 1
a build apparatus that performs a build process for forming a build object by melting a powdery material with an energy beam and then solidifying the melted material again
Data Source
AI summary
A build system is provided with: a build apparatus that performs a build process for forming a build object by supplying build materials to an irradiation area of an energy beam from a supply system while irradiating a target object with the energy beam from an irradiation system; and a change apparatus that is configured to change a relative position between the energy beam and the target object, wherein the build system differentiates a condition of the build process that is performed at a first area of the target object and a condition of the build process that is performed at a second area of the target object.