Additive Manufacturing Beam Control to Avoid Plume Interference
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The presence of emissions plumes in additive manufacturing can cause detrimental effects such as blockage or reduction in energy beam intensity, preventing rapid beam scanning or the use of multiple beams.
Innovation Solution
A method is employed to control the trajectory of energy beams or plumes in additive manufacturing processes, using models or real-time understanding of plume behavior to prevent intersections between energy beams and plumes, allowing for the avoidance of plumes through beam steering or zone division within the build surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rapid beam scanning or multiple beams are used, then productivity is improved, but beam intensity is reduced due to plume blockage
Solution Approach 1:
The system dynamically adjusts beam trajectories in real-time based on plume position and characteristics. The controller continuously modifies beam paths to avoid intersecting plumes, enabling rapid scanning while maintaining beam intensity by adapting to changing plume conditions during the additive manufacturing process.
Solution Approach 2:
The system changes beam parameters including trajectory, position, and timing to avoid plume interference. By modifying these parameters dynamically, the system achieves both rapid scanning and maintains sufficient beam intensity for effective powder fusion.
2Use of energy by moving object
If beam trajectory is controlled to avoid plumes, then beam intensity is maintained, but device complexity increases
Solution Approach 1:
The controller uses real-time feedback about plume position and behavior to adjust beam trajectories. This feedback mechanism enables the system to maintain beam intensity while managing complexity through intelligent, adaptive control rather than overly complex mechanical systems.
Solution Approach 2:
The system replaces complex mechanical beam steering mechanisms with computational control and software-based trajectory optimization. This substitution reduces physical complexity while maintaining the ability to avoid plume interference and preserve beam intensity.
3Productivity
If multiple beams are used, then productivity is improved, but harmful factors increase due to beam-plume interactions
Solution Approach 1:
The system segments the build surface into zones and assigns different beams to different zones, coordinating their operation to avoid simultaneous beam-plume interactions. This segmentation enables multiple beams to work in parallel while minimizing harmful interactions through spatial and temporal coordination.
Solution Approach 2:
The controller plans and coordinates beam trajectories in advance to prevent beam-plume interactions before they occur. By pre-coordinating multiple beam paths and timing, the system achieves high productivity while avoiding the harmful effects of beam-plume interference.
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 use of multiple energy beams or rapid scanning, improving part quality by maintaining uniform energy beam density and focus, while preventing beam-plume interactions that could lead to blockages or reduced intensity.
Implementation Method 1
the interaction of the radiant energy beam with the powder causes vaporization of the powder, generating a plume
Implementation Method 2
The shielding gas is used to transfer heat away from the surface of the powder bed
Data Source
AI summary
A method of controlling an additive manufacturing process in which one or more energy beams are used to selectively fuse a powder to form a workpiece, in the presence of one or more plumes generated by interaction of the one or more energy beams with the powder. The method includes controlling at least one of: a trajectory of the one or more plumes, and the one or more energy beams, so as to prevent the one or more energy beams from intersecting the one or more plumes.