Beam Shaping and Wire Feed for Accurate Metal 3D Forming
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Solution Overview
Problem
Existing metallic 3D printing technologies, such as PBF and DED, face challenges including insufficient fabrication accuracy, high surface roughness, slow processing speed, and cumbersome powder handling.
Innovation Solution
A shaping apparatus and method that employs a beam shaping system with a condensing optical system, a movement system for precise 6-DOF positioning, and a controller for coordinated control of the beam shaping and movement systems, allowing for the formation of three-dimensional shaped objects with improved accuracy and efficiency.
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 formed by laser melting powdered metal, but processing speed is slow
Solution Approach 1:
The patent implements continuous wire feeding into the laser melt pool, allowing uninterrupted material deposition and significantly faster processing compared to the layer-by-layer powder spreading and melting cycle of PBF
Solution Approach 2:
The patent changes the material delivery method from discrete powder layers to continuous wire feed, enabling sustained high-speed deposition while maintaining precision through controlled wire feeding rates and laser power
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
Solution Approach 1:
The patent replaces the powder handling and jetting system with a wire feeding mechanism that pushes solid wire through a nozzle, simplifying material handling while achieving superior dimensional accuracy and surface quality
Solution Approach 2:
The patent uses wire feedstock material that combines the advantages of ease of handling with the precision required for accurate fabrication, creating a composite approach that solves both handling and accuracy issues
3Loss of substance
If DED (Directed Energy Deposition) is used for metallic 3D printing, then powder is jetted only when necessary saving waste, but surface roughness remains high
Solution Approach 1:
The patent replaces the powder jetting system with wire feeding that delivers material directly to the melt pool in a controlled manner, achieving both material efficiency and smooth surface finish through precise wire feed control and optimized nozzle design
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, increased throughput, and improved handling of metal powders, 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
a condensing optical system, a movement system for precise 6-DOF positioning
Data Source
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AI summary
A shaping apparatus is equipped with: a beam shaping system (500) having a beam irradiation section (520) that includes a condensing optical system (82) which emits a beam and a material processing section (530) which supplies a shaping material irradiated by the beam from the beam irradiation section (520) ; 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 (500) such that a target portion (TA) on the target surface is shaped by supplying the shaping material from the material processing section (530) while moving the beam from the beam irradiation section (520) and the target surface (TAS) on a workpiece (W) (or a table (12)) relative to each other. Further the intensity distribution of the beam in the shaping plane (MP) facing the emitting surface of the condensing optical system can be modified. Consequently, it becomes possible for three-dimensional shaped obj ects with excellent processing accuracy to be formed on the target surface.