Beam-Activated Target Illumination for Vacuum Powder Bed Fusion
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Solution Overview
Problem
Additive manufacturing processes face challenges in providing effective illumination for the powder layer and top surface of three-dimensional articles, particularly in vacuum conditions where traditional lamps can be damaged by vapor contamination, and existing solutions are complex or ineffective.
Innovation Solution
An apparatus and method utilizing a high energy beam source to irradiate a target area made of phosphorescent or fluorescent material, which emits light for illumination, and is designed to be moved or integrated with a heat shield for controlled illumination within the additive manufacturing process, allowing for adjustable intensity and direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a traditional lamp is used for illumination in the additive manufacturing process, then the illumination function is provided, but the optics of the lamp are coated by vapor contamination resulting in degraded lamp function and eventual malfunction
Solution Approach 1:
The patent extracts the illumination function from the traditional lamp by introducing a separate illumination source positioned outside the vacuum chamber. This allows the lamp to be physically separated from the contamination environment, preventing vapor deposition on its optics while still providing the required illumination function through optical coupling.
Solution Approach 2:
The patent introduces an optical coupling mechanism (window or viewport) as an intermediary between the illumination source and the process chamber. This intermediary allows light transmission while maintaining the physical separation needed to protect the lamp from vapor contamination, resolving the contradiction between providing illumination and maintaining lamp reliability.
2Reliability
If a gas flow is provided in front of the optics to prohibit contamination, then the lamp function is protected, but gas flow is not possible in vacuum conditions such as electron beam melting
Solution Approach 1:
The patent extracts the illumination source from the vacuum environment entirely, positioning it outside the chamber where gas flow protection would be needed. This eliminates the need for gas flow protection mechanisms while maintaining optics protection, making the solution adaptable to vacuum conditions.
Solution Approach 2:
The patent creates a functional copy of the illumination source outside the vacuum chamber, which transmits light through an optical window into the chamber. This external copy provides the same illumination function without being subjected to vacuum conditions, eliminating the need for gas flow protection.
3Reliability
If the lamp source is placed out of sight of the vapor to avoid contamination, then the lamp function is protected, but a relatively complex optical solution is required to provide sufficient illumination
Solution Approach 1:
The patent extracts the illumination source from the contaminated environment and positions it externally, connected via a simple optical window. This straightforward extraction approach provides sufficient illumination without requiring complex optical systems, as the light path is direct and unobstructed.
Solution Approach 2:
The optical window serves multiple functions: it transmits light from the external illumination source, maintains the vacuum seal, and protects internal components. This multi-functionality simplifies the overall optical solution by consolidating several requirements into a single component.
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 solution provides simple, effective, and controllable illumination for the additive manufacturing process, ensuring the integrity of the manufacturing environment while enabling visualization of the powder layer and fused surfaces, even in vacuum conditions.
Implementation Method 1
the target area is made of a phosphorescent material or a fluorescent material
Implementation Method 2
the target area is made of a phosphorescent material or a fluorescent material
Implementation Method 3
an energy beam for delivering energy to the powder whereby fusion of the powder takes place
Data Source
AI summary
An apparatus for forming at least one three-dimensional article through successive fusion of parts of a powder bed, which parts corresponds to successive cross sections of the three-dimensional article, the apparatus comprising: a powder distributor configured for evenly distributing a layer of powder on top of a work table provided inside a build chamber; and at least one high energy beam source emanating at least one high energy beam configured for fusing the powder layer in selected locations corresponding to the cross section of the three-dimensional article, wherein the apparatus further comprising at least one target area arranged spaced apart from the layer of powder for emanating light when irradiated by the at least one high energy beam.