Additive Manufacturing Beam Parameters for Angle-of-Incidence Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current additive manufacturing techniques often result in suboptimal surface and sub-surface quality, leading to increased post-processing costs and potential scrap rates due to inadequate consideration of build part positioning relative to the manufacturing instrument, which affects the angle of incidence of energy beams and subsequent surface roughness and porosity.
Innovation Solution
An additive manufacturing system that determines and adjusts beam parameters based on geometrical characteristics such as the angle of incidence between the beam line and the surface normal of each segment of the build part, allowing for the selection of distinct beam parameters for different segments to improve surface quality and reduce post-processing needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single set of beam parameters is used for the entire build part, then the manufacturing process is simple and fast, but the surface and sub-surface quality deteriorates leading to increased post-processing needs
Solution Approach 1:
The build part is divided into multiple segments based on geometrical characteristics such as angle of incidence. Each segment is then assigned a specific set of beam parameters optimized for its particular geometrical features, allowing differential control to improve surface and sub-surface quality without requiring complete system redesign
Solution Approach 2:
Different beam parameters (power, velocity, hatching pattern, offset) are applied to different segments of the build part based on their local geometrical characteristics. This enables each segment to receive optimized processing conditions tailored to its specific angle of incidence and surface requirements, improving overall manufacturing precision
2Manufacturing precision
If build part position is determined without considering angle of incidence, then the positioning process is simple and quick, but the surface roughness and porosity increase requiring costly post-processing
Solution Approach 1:
The system performs preliminary determination of build part positioning by evaluating geometrical characteristics and angle of incidence before the actual manufacturing process begins. This advance planning allows optimization of beam parameters for each segment without adding significant time to the production schedule, as the analysis is performed computationally prior to manufacturing
3Manufacturing precision
If uniform beam parameters are applied to all segments, then the manufacturing process is efficient and fast, but the dimensional accuracy and quality of specific segments deteriorate
Solution Approach 1:
The beam parameters are made dynamic and adaptive rather than static and uniform. The system automatically adjusts power, velocity, hatching pattern, and offset parameters based on the real-time geometrical characteristics of each segment being manufactured, enabling high precision dimensional accuracy while maintaining manufacturing efficiency through automated parameter selection
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 enhances the surface and sub-surface quality of build parts, reducing the need for costly post-processing and minimizing scrap rates by optimizing beam parameters according to the specific geometrical characteristics of each segment, thereby improving dimensional accuracy and manufacturing efficiency.
Implementation Method 1
The deposited layers are selectively fused via the application of a focused energy source, such as a laser, which heats and bonds the material
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
An additive manufacturing system (100) comprising: one or more processors (118) configured to determine one or more geometrical characteristics of each of multiple segments (408) of a build part (402) at a candidate position of the build part relative to an additive manufacturing instrument (101), wherein the one or more geometrical characteristics include an angle of incidence (420) between a beam line (210, 248) extending from a beam emitter (106) of the additive manufacturing instrument and a surface normal (212, 250) of a respective skin (214) of the corresponding segment proximate to the beam line, wherein the one or more processors are configured to select, based on the one or more geometrical characteristics of the segments that are determined, a first set of beam parameters for forming a first segment (408A) of the segments of the build part and a second set of beam parameters for forming a second segment (408B) of the segments of the build part, wherein at least one of the beam parameters in the second set differs from the beam parameters in the first set.