3D Build Layer Irradiation Sequence for Thermal Accumulation Control

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Solution Overview

Problem

Existing additive manufacturing methods face challenges in controlling thermal energy input during selective irradiation, leading to undesired heat accumulation in border regions of irradiation areas, which negatively affects the structural properties of the manufactured three-dimensional objects.

Innovation Solution

The method involves selectively irradiating build material layers with energy beams, using irradiation patterns that differentiate between sub-areas with varying heat conductance capabilities, where areas with lower heat conductance are irradiated first to allow thermal energy dissipation into areas with higher heat conductance, thereby reducing thermal energy accumulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If uniform irradiation is applied across the entire irradiation area, then manufacturing efficiency is maintained, but thermal energy accumulates in border regions leading to degraded structural properties

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidstructural properties

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The irradiation area is segmented into different zones based on heat conductance characteristics. Border regions with lower heat conductance are identified and treated differently from inner regions with higher heat conductance, allowing tailored thermal management across the irradiation area

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different irradiation parameters are applied to different regions of the irradiation area. Border regions receive reduced thermal energy input compared to inner regions, creating locally optimized thermal conditions that prevent heat accumulation while maintaining overall manufacturing efficiency

Inventive Principle:

Principle #3Local quality

2Strength

If thermal energy input is increased to improve consolidation quality, then structural properties improve, but heat accumulation in border regions worsens

Engineering Contradiction:

Improvestructural propertiesVSAvoidthermal energy accumulation

Core Design Contradiction:

StrengthVSTemperature

Solution Approach 1:

The method applies locally differentiated thermal energy input where inner regions receive higher energy for quality consolidation while border regions receive reduced energy to prevent heat accumulation, achieving both goals simultaneously through spatially varying parameters

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Irradiation parameters such as power, speed, or pattern are dynamically adjusted based on the spatial location within the irradiation area, creating a gradient of thermal energy input that adapts to local heat conductance conditions and prevents harmful temperature accumulation

Inventive Principle:

Principle #35Parameter changes

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 approach improves the structural properties of the manufactured objects by reducing thermal energy accumulation and enhancing heat dissipation, resulting in better mechanical properties.

Implementation Method 1

selective irradiation and consolidation of build material layers, whereby each build material layer which is selectively irradiated and consolidated comprises at least one irradiation area which is irradiated and consolidated by means of at least one energy beam

Methodology Applied

Scientific EffectElectromagnetic energy to thermal energy transformation: Dielectric Heating

Implementation Method 2

selective electron beam melting processes or selective laser melting processes

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

selective laser sintering method

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentEP3640007B1Method for additively manufacturing at least one three-dimensional object

Publication Date: 2023.12.27 CONCEPT LASER

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AI summary

Method for additively manufacturing at least one three-dimensional object (2) by means of successive layerwise selective irradiation and consolidation of build material layers (3), whereby each build material layer (3) which is selectively irradiated and consolidated comprises at least one irradiation area (IA) which is irradiated and consolidated by means of at least one energy beam (5), wherein the irradiation area (IA) comprises at least one first sub-area (SA1) having a first heat conductance capability defined by its orientation and/or position relative to non-consolidated build material areas adjacent to the irradiation area (IA) and at least one second sub-area (SA2) having a second heat conductance capability higher than the first heat conductance capability of the first sub-area (SA1) defined by its orientation and/or position relative to non-consolidated build material areas adjacent to the irradiation area (IA), whereby for at least one irradiation area of at least one build material layer (3) which is to be selectively irradiated and consolidated a respective first sub-area (SA1) is irradiated before a respective second sub-area (SA2).