3D Build Plane Irradiation Scheduling Under Process Gas Flow
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Solution Overview
Problem
Current additive manufacturing methods face challenges in optimizing the scheduling of start times for selectively irradiating and consolidating layers of build material due to the complex interaction of process parameters, particularly the streaming behavior of the process gas stream, which affects the removal of fume, smoke, and soot particles.
Innovation Solution
A method that utilizes a control unit to determine if a process gas stream charged with particles generated during selective irradiation and consolidation meets pre-defined scheduling criteria, such as time or local criteria, to determine optimal start times for irradiating and consolidating layers of build material, ensuring efficient particle removal and minimizing interference between areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the process gas stream velocity is increased to improve particle removal efficiency, then particle removal effectiveness improves, but the scheduling complexity of multi-area irradiation increases
Solution Approach 1:
The system performs preliminary simulation of gas stream particle transport before actual irradiation scheduling. The control unit calculates predicted particle transport paths and arrival times at different build areas in advance, allowing the scheduling system to plan irradiation sequences that prevent particle contamination without requiring complex real-time adjustments during the manufacturing process
Solution Approach 2:
The system uses simulation-based feedback to optimize scheduling decisions. By modeling the gas stream behavior and particle transport, the control unit receives feedback information about where particles will travel and when they will arrive, allowing it to adjust the irradiation schedule to avoid contaminating areas that have not yet been irradiated
2Manufacturing precision
If the start time for irradiating subsequent areas is delayed to allow particle removal, then particle contamination is reduced, but build time increases
Solution Approach 1:
The system performs preliminary simulation of gas stream particle transport before actual irradiation scheduling. The control unit calculates predicted particle transport paths and arrival times at different build areas in advance, allowing the scheduling system to plan irradiation sequences that prevent particle contamination without requiring complex real-time adjustments during the manufacturing process
Solution Approach 2:
The irradiation schedule is dynamically adjusted based on the simulated gas stream behavior. The control unit determines optimal start times for irradiating different areas by considering the dynamic transport of particles through the gas stream, allowing flexible scheduling that minimizes both particle contamination and total build time
3Productivity
If multiple areas are irradiated simultaneously to reduce build time, then productivity improves, but particle contamination of subsequent areas increases
Solution Approach 1:
The system performs preliminary simulation of gas stream particle transport before actual irradiation scheduling. The control unit calculates predicted particle transport paths and arrival times at different build areas in advance, allowing the scheduling system to plan irradiation sequences that prevent particle contamination without requiring complex real-time adjustments during the manufacturing process
Solution Approach 2:
The system applies different irradiation timing strategies to different areas of the build plane based on their local characteristics and gas stream exposure. The control unit determines area-specific start times for irradiation, allowing simultaneous irradiation in areas where particle contamination is not a concern while sequencing irradiation in areas where particles would contaminate the build
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 allows for improved scheduling of start times, reducing build times and ensuring that particles generated during irradiation and consolidation do not negatively affect subsequent irradiation and consolidation processes, thereby enhancing the efficiency and quality of the additive manufacturing process.
Implementation Method 1
a process gas stream being capable of being charged with particles generated during selective irradiation and consolidation of respective layers of build material streams across the build plane, whereby the process gas stream is adapted to remove or transport respective particles from a layer of build material
Implementation Method 2
selective irradiation and consolidation of layers of build material by means of at least one energy beam
Implementation Method 3
selective laser melting processes
Implementation Method 4
consolidation of layers of build material by means of at least one energy beam
Data Source
Figure 1
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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 layers of build material (3) applied in a build plane (BP) of an apparatus (1) for additively manufacturing three-dimensional objects (2) by means of at least one energy beam (4), whereby - a process gas stream being capable of being charged with fume particles generated during selective irradiation and consolidation of respective layers of build material (3) streams across the build plane (BP), whereby the process gas stream is adapted to transport respective fume particles from a layer of build material (3) which are generated during selective irradiation and consolidation of the respective layer of build material (3); wherein - for at least one layer of build material (3) which comprises a first area (A1) which is to be irradiated and consolidated and at least one further area (A2) which is to be irradiated and consolidated, it is determined that the process gas stream being chargeable or charged with fume particles generatable or generated during irradiation and consolidation of at least one of the areas (A1 - An) which are to be irradiated and consolidated fulfils a pre-definable or pre-defined scheduling criterion; wherein - the start time for starting irradiating and consolidating of the first area (A1) and/or the start time for starting irradiating and consolidating the at least one further area (A2, An) is determined on the basis of the determination that the process gas stream has fulfilled the pre-definable or pre-defined scheduling criterion.