Beam-Guided Metal Shaping on Moving Surfaces for 3D Accuracy

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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, which hinder the economic rationality and convenience of manufacturing three-dimensional shaped objects.

Innovation Solution

A shaping apparatus and method that incorporate a movement system, measurement system, and beam shaping system controlled by a controller to precisely position and irradiate a beam on a target surface, allowing for the relative movement of the target surface and beam while supplying shaping material, thereby improving processing accuracy and efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If PBF (Powder Bed Fusion) is used for metallic 3D printing, then three-dimensional shaped objects can be fabricated, but processing speed is slow

Engineering Contradiction:

Improveprocessing speedVSAvoidfabrication accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent replaces the slow mechanical powder spreading and sequential laser melting process with a high-speed electron or ion beam deposition system. The beam can be rapidly scanned and positioned, and material is deposited directly without the time-consuming powder bed preparation steps, significantly increasing processing speed while maintaining or improving accuracy through precise beam control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent enables continuous material deposition and beam scanning operations without the intermittent powder spreading steps required in PBF. The electron or ion beam continuously melts and deposits material as it scans across the workpiece surface, eliminating idle time between layers and maintaining high productivity throughout the manufacturing process.

Inventive Principle:

Principle #20Continuity of useful action

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

Engineering Contradiction:

Improvepowder handlingVSAvoidfabrication accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent replaces the powder-based DED system with an electron or ion beam-based material deposition system. Instead of jetting and melting powder particles, the invention uses a focused electron or ion beam to melt and deposit material directly from a solid or liquid source through a nozzle, eliminating powder handling entirely while achieving superior fabrication accuracy through precise beam control and direct material placement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of substance

If DED (Directed Energy Deposition) is used for metallic 3D printing, then processing can be performed without large amounts of surplus powder, but surface finish roughness remains high

Engineering Contradiction:

Improvepowder wasteVSAvoidsurface finish

Core Design Contradiction:

Loss of substanceVSManufacturing precision

Solution Approach 1:

The patent replaces the powder deposition and melting system with an electron or ion beam-based direct deposition system. Material is delivered directly to the beam focus point and deposited with precise control, eliminating the need for large amounts of surplus powder and achieving smooth surface finish through controlled material placement and beam parameters without the roughness associated with powder particle deposition.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 improved economic rationality by optimizing the movement and irradiation of the beam in conjunction with material supply, addressing the limitations of existing metallic 3D printing 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

Methodology Applied

Scientific EffectLaser beam melting: Laser

Implementation Method 2

a measurement system that acquires position information of the target surface in a state movable by the movement system

Methodology Applied

Scientific EffectPosition detection:

Data Source

PatentUS20240033853A1Shaping apparatus and shaping method

Publication Date: 2024.02.01 NIKON CORP

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.