3D Printing Beam Modulation for Local Melt Uniformity
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Solution Overview
Problem
Existing additive layer manufacturing techniques struggle to achieve consistent quality in three-dimensional workpieces due to inhomogeneities in process parameters, leading to issues such as fumes and particulate emissions that affect the interaction between the irradiation beam and the material, resulting in non-homogeneous production.
Innovation Solution
A system and method that modulates the irradiation beam properties based on local process parameters, including process gas properties and thermal radiation, to counteract inhomogeneities by adjusting energy input intensity, temporal spacing, and beam characteristics across the irradiation plane, dividing it into zones for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a laser beam is used to selectively irradiate and melt or sinter powder layers in additive manufacturing, then three-dimensional workpieces of complex shapes can be produced, but inhomogeneities in process parameters lead to non-homogeneous material interaction and reduced workpiece quality
Solution Approach 1:
The patent applies local quality by modulating the laser beam power dynamically across different zones of the irradiation plane. The control unit divides the build area into multiple zones and assigns different power levels to each zone based on local process parameters such as gas flow velocity and thermal radiation measurements. This ensures that each local area receives the appropriate energy input to achieve homogeneous material interaction despite variations in the manufacturing environment.
Solution Approach 2:
The patent implements parameter changes by continuously adjusting the laser beam power parameter in response to measured local process conditions. The system monitors thermal radiation and gas flow characteristics, then modifies the irradiation power parameter in real-time to compensate for inhomogeneities. This dynamic parameter adjustment maintains consistent material interaction across the entire build area while preserving the ability to manufacture complex geometries.
2Manufacturing precision
If the irradiation beam power is increased to improve melting or sintering quality, then material interaction improves, but fumes and particulate emissions increase affecting beam quality
Solution Approach 1:
The patent implements feedback control by measuring thermal radiation from the irradiation zone and using this information to dynamically adjust the laser beam power. The system continuously monitors the thermal environment and process gas characteristics, then modifies the irradiation power in real-time to maintain optimal material interaction while preventing excessive fume generation. This closed-loop control ensures that quality improvements do not come at the cost of increased harmful emissions.
Solution Approach 2:
The patent applies dynamics by making the irradiation beam power adjustable and responsive to changing process conditions rather than using a fixed power level. The system dynamically adapts the power parameter based on real-time measurements of thermal radiation and gas flow, allowing optimal power levels to be maintained throughout the manufacturing process. This dynamic adjustment prevents both under-heating and excessive fume generation while maintaining consistent material interaction quality.
3Object-generated harmful factors
If process gas flow is increased to remove fumes and particulate emissions, then harmful factors are reduced, but inhomogeneities in gas flow velocity across the irradiation plane increase
Solution Approach 1:
The patent applies local quality by measuring and compensating for local variations in gas flow velocity across different zones of the irradiation plane. The system divides the build area into multiple zones and adjusts the laser beam power in each zone according to the local gas flow characteristics. This ensures that areas with lower gas flow velocity receive reduced power to prevent fume accumulation, while areas with higher velocity receive appropriate power for optimal material interaction, maintaining overall process uniformity despite gas flow inhomogeneities.
Solution Approach 2:
The patent implements parameter changes by adjusting the irradiation power parameter in response to measured gas flow velocity variations. The control unit modifies the power parameter locally in different zones to compensate for the non-uniform gas flow distribution. This dynamic parameter adjustment ensures consistent material interaction and fume management across the entire build area, transforming the problematic gas flow inhomogeneity into a manageable condition through adaptive 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
Improves the homogeneity and quality of three-dimensional workpieces by effectively managing fumes and particulate emissions, ensuring consistent material interaction and reducing the impact of inhomogeneities during the additive layer manufacturing process.
Implementation Method 1
a raw material powder layer is applied onto a carrier and subjected to, for example, laser radiation in a site selective manner... The laser radiation penetrating into the powder layer causes heating and consequently melting or sintering of the raw material powder particles
Implementation Method 2
The laser radiation penetrating into the powder layer causes heating and consequently melting or sintering of the raw material powder particles
Implementation Method 3
The laser radiation penetrating into the powder layer causes heating and consequently melting or sintering of the raw material powder particles
Implementation Method 4
a control unit coupled to the irradiation unit and configured to control the irradiation unit to modulate, as a function of a local process parameter when producing the three-dimensional workpiece, a (local) irradiation beam property of the irradiation beam
Implementation Method 5
effectively managing fumes and particulate emissions, ensuring consistent material interaction and reducing the impact of inhomogeneities during the additive layer manufacturing process
Data Source
AI summary
We describe a system for use in an apparatus for producing a three-dimensional workpiece using an additive layer manufacturing technique, the system comprising: an irradiation unit configured to selectively irradiate an irradiation plane with an irradiation beam, and a control unit coupled to the irradiation unit and configured to control the irradiation unit to modulate, as a function of a local process parameter when producing the three-dimensional workpiece, an irradiation beam property of the irradiation beam.