Beam-Guided Metal Shaping With Surface Position Feedback
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Solution Overview
Problem
Metallic 3D printing technologies, such as PBF and DED, face issues with fabrication accuracy, surface finish roughness, processing speed, and cumbersome powder handling, limiting their economic rationality and convenience in manufacturing.
Innovation Solution
A shaping apparatus and method that utilize a movement system, measurement system, and beam shaping system controlled by a controller to form three-dimensional objects with improved accuracy, using a beam irradiation section and material processing section to apply shaping material based on 3D data and position information, enabling precise and efficient formation of metallic objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If PBF (Powder Bed Fusion) is used for metallic 3D printing, then three-dimensional objects can be formed by layer-by-layer processing, but processing speed is slow
Solution Approach 1:
The patent replaces the slow mechanical processes of powder spreading, layer formation, and sequential melting with a direct beam-based energy deposition system that can process material continuously at higher speeds while maintaining precision through digital control of beam parameters
Solution Approach 2:
The patent enables continuous or near-continuous processing by eliminating the intermittent powder spreading and layer formation steps inherent in PBF, allowing the beam to continuously deposit and solidify material in a seamless process that increases processing speed while maintaining fabrication accuracy
2Ease of operation
If DED (Directed Energy Deposition) is used for metallic 3D printing, then powder handling is improved compared to PBF, but fabrication accuracy remains insufficient and surface finish is rough
Solution Approach 1:
The patent replaces the powder-based deposition system with a direct material feed system where material is delivered precisely to the beam focus point, eliminating powder handling issues while achieving higher fabrication accuracy through controlled material flow and beam parameter optimization
Solution Approach 2:
The patent applies local quality control by precisely controlling material delivery and beam parameters at each deposition location, ensuring optimal material utilization and high fabrication accuracy at the point of energy deposition while maintaining ease of operation through automated material feeding
3Loss of substance
If DED (Directed Energy Deposition) is used for metallic 3D printing, then waste of powder is reduced by jetting only when necessary, but processing speed remains slow
Solution Approach 1:
The patent replaces the jetted powder deposition system with a direct material feed system coupled with a focused beam, enabling continuous material deposition without the intermittent jetting process, thereby increasing processing speed while maintaining low material waste through precise control
Solution Approach 2:
The patent enables continuous material deposition and beam processing, eliminating the intermittent jetting and positioning cycles in DED, which significantly increases processing speed while maintaining efficient material utilization through continuous monitoring and control
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
The solution enables the formation of three-dimensional shaped objects with enhanced processing accuracy and efficiency, improving the economic rationality and convenience of metallic 3D printing by addressing the limitations of existing technologies.
Implementation Method 1
a high power laser beam is scanned thereon using a galvano mirror or the like, and the part where the beam hits is melted and solidified
Implementation Method 2
the part where the beam hits is melted and solidified
Implementation Method 3
The powdered metal melts into a liquid form by irradiation of a laser. When the processing subject is located around the focus, the liquefied metal is deposited on the processing subject, cooled, and then is solidified again
Data Source
AI summary
This shaping apparatus is equipped with: a movement system which moves a target surface; a measurement system for acquiring position information of the target surface in a state movable by the movement system, a beam shaping system that has a beam irradiation section and a material processing section which supplies a shaping material irradiated by a beam from beam irradiation section; and a controller. On the basis of 3D data of a three-dimensional shaped object to be formed on a target surface and position information of the target surface acquired using the measurement system, the controller controls the movement system and the beam shaping system such that a target portion on the target surface is shaped by supplying the shaping material while moving the target surface and the beam from beam irradiation section relative to each other.