Additive Manufacturing Beam Steering to Avoid Plume Interference
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Solution Overview
Problem
The presence of emissions plumes in additive manufacturing can cause detrimental effects such as blockage or reduction in beam intensity, preventing rapid beam scanning or the use of multiple beams due to condensate interference.
Innovation Solution
A method using real-time understanding of plume behavior and a controller to adjust the path of the energy beam, avoiding plumes by creating a plume map and employing techniques like beam steering or zone division to prevent interactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rapid beam scanning or multiple beams are used, then productivity is improved, but beam blockage or intensity reduction occurs due to plume interference
Solution Approach 1:
The system dynamically adjusts the beam path in real-time based on detected plume position and characteristics. The controller continuously modifies beam trajectory parameters to navigate around plumes, enabling rapid scanning while maintaining consistent beam intensity and avoiding blockage by condensate.
Solution Approach 2:
The system uses sensors to detect plume position, density, and movement in real-time, feeding this information back to the controller. The controller then adjusts the beam path accordingly, creating a closed-loop control system that maintains beam reliability while enabling high-speed scanning through adaptive plume avoidance.
2Productivity
If multiple energy beams are used, then productivity is improved, but beam-plume interactions cause detrimental effects
Solution Approach 1:
The system divides the build chamber into multiple operational zones and assigns different beams to specific zones. The controller coordinates beam paths to operate in separate spatial regions, reducing beam-plume interactions while maintaining high productivity through parallel processing in segmented areas.
Solution Approach 2:
The system uses multiple beams operating at different spatial dimensions and angles, with the controller coordinating their paths to avoid plume interference. By utilizing three-dimensional space efficiently and steering beams around plumes in multiple directions, the system enables parallel processing without beam blockage.
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
Enables the use of multiple energy beams or rapid scanning, improving part quality by maintaining uniform energy beam density and focus, and preventing beam blockage or intensity reduction.
Implementation Method 1
the interaction of the radiant energy beam with the powder causes vaporization of the powder, generating a plume
Implementation Method 2
The shielding gas is used to transfer heat away from the surface of the powder bed
Implementation Method 3
the vapor cools and condenses so that the plume comprises a mixture of gas and metallic particles (condensate)
Data Source
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AI summary
A method of controlling an additive manufacturing process in which one or more energy beams are used to selectively fuse a powder to form a workpiece, in the presence of one or more plumes generated by interaction of the one or more energy beams with the powder. The method includes controlling at least one of: a trajectory of the one or more plumes, and the one or more energy beams, so as to prevent the one or more energy beams from intersecting the one or more plumes.