Build Data Segmentation for Mixed Precision Additive Manufacturing
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Solution Overview
Problem
In existing build data generating devices for three-dimensional powder bed fusion additive manufacturing, only one manufacturing condition can be applied to one cross-sectional shape, leading to inappropriate manufacturing conditions when shape elements with opposing conditions are mixed, resulting in suboptimal shape reproducibility and manufacturing speed.
Innovation Solution
A build data generating device that segments a cross-sectional shape into fine and coarse regions and applies different manufacturing conditions to each region, allowing for appropriate conditions to be applied even when opposing conditions are present.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single manufacturing condition is applied to the entire cross-sectional shape, then the device complexity is reduced and the process is simplified, but the manufacturing precision deteriorates when shape elements with opposing conditions are mixed
Solution Approach 1:
The cross-sectional shape is segmented into multiple regions (first region and second region) based on shape elements, allowing different manufacturing conditions to be applied to each region. This segmentation enables high-precision manufacturing for elements requiring fine conditions while maintaining simplified processing for elements suitable for coarse conditions, thus resolving the contradiction between manufacturing precision and device complexity.
Solution Approach 2:
Different manufacturing conditions are applied to different regions of the cross-sectional shape based on the specific requirements of shape elements in each region. The first manufacturing condition is applied to the first region containing elements requiring fine manufacturing, while the second manufacturing condition is applied to the second region containing elements suitable for coarse manufacturing. This local quality approach ensures each element receives appropriate conditions without increasing overall system complexity.
2Manufacturing precision
If a manufacturing condition excellent in shape reproducibility is applied to the entire cross-sectional shape, then the manufacturing precision is improved, but the productivity decreases due to slower manufacturing speed
Solution Approach 1:
The cross-sectional shape is divided into regions requiring high precision and regions where speed is prioritized. By segmenting the build data into first and second regions with different manufacturing conditions, the system applies precision-optimized conditions only where necessary, while using faster conditions in other areas, thus maintaining shape reproducibility while improving overall manufacturing speed and productivity.
Solution Approach 2:
The manufacturing conditions are optimized locally for each region: the first manufacturing condition with parameters optimized for shape reproducibility is applied to the first region, while the second manufacturing condition with parameters optimized for speed is applied to the second region. This local optimization ensures high precision where needed without sacrificing overall productivity.
3Productivity
If a manufacturing condition enabling high-speed manufacturing is applied to the entire cross-sectional shape, then the productivity is improved, but the manufacturing precision deteriorates at parts requiring fine manufacturing
Solution Approach 1:
The build data is segmented into first and second regions based on the characteristics of shape elements. This segmentation allows the system to apply high-speed manufacturing conditions to the second region while maintaining precision-optimized conditions for the first region, thus achieving high overall productivity without sacrificing the shape reproducibility of elements requiring fine manufacturing.
Solution Approach 2:
Different manufacturing conditions are applied locally to different regions: the second manufacturing condition optimized for speed is applied to the second region containing elements suitable for coarse manufacturing, while the first manufacturing condition optimized for precision is applied to the first region. This local differentiation maintains shape reproducibility for precision-critical elements while achieving high-speed manufacturing overall.
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 manufacturing of entire cross-sectional shapes under appropriate conditions, achieving both high shape reproducibility and efficient manufacturing speed.
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
Even when shape elements having opposing appropriate manufacturing conditions are mixed in one cross-sectional shape, the entire cross-sectional shape is manufactured under an appropriate manufacturing condition. A build data generating device generating build data for controlling a three-dimensional powder bed fusion additive manufacturing apparatus that manufactures an article by melting a cross-sectional shape of each layer by irradiation of a beam includes: a region segmentation unit that performs processing for segmenting the cross-sectional shape cut out from three-dimensional shape data of the article into a fine region and a coarse region; and a condition application unit that applies different manufacturing conditions to the fine region and the coarse region segmented by the region segmentation unit to generate the build data.