Beam Shaping for Wire-Fed 3D Metal Printing Accuracy
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Solution Overview
Problem
Existing 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, a beam shaping system with a condensing optical system, and a controller to control the movement and beam irradiation based on 3D data, allowing for precise control of the beam intensity distribution and material supply to achieve high processing accuracy.
Engineering Contradictions & Design Principles
Engineering 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
Solution Approach 1:
The patent implements continuous wire feeding combined with continuous laser melting, eliminating the intermittent powder spreading steps required in PBF. This continuous processing approach increases productivity while maintaining fabrication accuracy through precise control of wire feed rate and laser power parameters
2Ease of operation
If DED (Directed Energy Deposition) is used for metallic 3D printing, then powder handling is improved, but fabrication accuracy remains insufficient
Solution Approach 1:
The patent replaces the powder handling and jetting system in DED with a wire feeding system. This substitution maintains the ease of material supply while dramatically improving fabrication accuracy through precise wire positioning and controlled melting, eliminating the accuracy limitations of powder-based deposition
3Loss of substance
If DED (Directed Energy Deposition) is used for metallic 3D printing, then material waste is reduced, but surface finish roughness remains high
Solution Approach 1:
The patent changes the deposition form from powder to wire, which maintains low material waste through precise wire feeding control while simultaneously improving surface finish. The wire-based approach allows for more controlled melting and solidification, reducing the roughness inherent in powder-based DED processes
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 improved processing accuracy, increased efficiency, and enhanced economic rationality in manufacturing by optimizing the movement and beam shaping processes.
Implementation Method 1
a beam irradiation section including a condensing optical system which emits a beam
Implementation Method 2
a condensing optical system which emits a beam and a material processing section which supplies shaping material to be irradiated by the beam from the beam irradiation section
Implementation Method 3
The powdered metal melts into a liquid form by irradiation of a laser
Implementation Method 4
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 5
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
A shaping apparatus is equipped with: a beam shaping system having a beam irradiation section that includes a condensing optical system which emits a beam and a material processing section which supplies a shaping material irradiated by the beam from the beam irradiation section; and a controller which, on the basis of 3D data of a three-dimensional shaped object to be formed on a target surface, controls a workpiece movement system and the beam shaping system such that a target portion on the target surface is shaped by supplying the shaping material from the material processing section while moving the beam from the beam irradiation section and the target surface on a workpiece (or a table) relative to each other. Further the intensity distribution of the beam in the shaping plane facing the emitting surface of the condensing optical system can be modified.