Build Data Generating Device Scanning Line Density Control
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Solution Overview
Problem
In three-dimensional powder bed fusion additive manufacturing, the existing build data generating devices often result in scanning lines that are either too far apart or too close, leading to melting defects due to insufficient or excessive melting.
Innovation Solution
A build data generating device that generates correction scanning lines in areas where the arrangement of scanning lines becomes sparse or dense, thereby adjusting the density of scanning lines to prevent melting defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a predetermined beam scanning method is used to generate scanning lines, then the manufacturing process is simple and efficient, but the scanning line arrangement becomes non-uniform causing melting defects
Solution Approach 1:
The patent applies preliminary action by detecting the cross-sectional shape of the manufactured object before generating scanning lines, and pre-calculating the optimal scanning line arrangement based on the actual geometry. This allows the system to anticipate and correct for potential non-uniformities in scanning line distribution before the additive manufacturing process begins, ensuring uniform melting without requiring complex real-time adjustments during manufacturing.
Solution Approach 2:
The patent implements local quality by generating scanning lines with locally optimized spacing based on the specific cross-sectional shape characteristics. Instead of using a uniform global scanning pattern, the system adjusts scanning line density and arrangement according to local geometric features such as curvature and cross-sectional area variations, ensuring appropriate melting coverage for each specific region of the manufactured object.
2Loss of time
If scanning lines are generated too sparsely, then the manufacturing time is reduced, but insufficient melting occurs causing defects
Solution Approach 1:
The patent applies dynamics by making the scanning line spacing adaptive rather than fixed. The system dynamically adjusts the distance between scanning lines based on local cross-sectional characteristics, allowing closer spacing in regions requiring more melting energy and wider spacing in regions where less energy is needed. This dynamic optimization ensures complete melting reliability while minimizing unnecessary manufacturing time.
3Reliability
If scanning lines are generated too densely, then melting completeness is improved, but excessive melting occurs causing defects
Solution Approach 1:
The patent implements parameter changes by varying the scanning line spacing parameter according to the cross-sectional shape parameters. The system calculates optimal scanning line intervals based on quantitative geometric parameters such as cross-sectional area, perimeter, and curvature radius, dynamically adjusting the spacing parameter to achieve precise melting control for each specific region without causing excessive melting.
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 proposed solution reduces variation in scanning line density, preventing melting defects and improving the consistency and quality of the manufactured articles.
Implementation Method 1
a surface (hereinafter, also referred to as a 'manufactured surface') of a powder layer formed by spreading powder with a predetermined thickness is selectively irradiated with a beam to melt and solidify a portion having a cross-sectional shape of an article to be manufactured
Data Source
AI summary
Provided is a technique capable of reducing variation in density of scanning lines when generating the scanning lines for manufacturing an article by three-dimensional powder bed fusion additive manufacturing. A build data generating device generates build data for controlling the three-dimensional powder bed fusion additive manufacturing apparatus that melts the cross-sectional shape of each layer by irradiation of a beam to manufacture the article. The build data generating device includes a build data generating unit that generates a plurality of scanning lines in a region of the cross-sectional shape cut out from three-dimensional shape data of the article by a predetermined beam scanning method, and generates correction scanning lines in a portion where the arrangement of the scanning lines becomes sparse and/or a portion where the arrangement of the scanning lines becomes dense.