Build Plane Material Dosing for Precise Additive Manufacturing
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Solution Overview
Problem
Current methods for determining the amount of build material in additive manufacturing rely on static dosing factors based on empirical values, which do not allow for adjustments, leading to inefficient material consumption and lack of precision in layer formation.
Innovation Solution
A method that subdivides the build plane into categories and sub-categories based on their irradiation and consolidation requirements, using a software-controlled algorithm to determine the precise amount of build material needed for each layer, considering the specific areas to be selectively irradiated and consolidated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If static build material dosing factors based on empirical values are used, then the determination process is simple, but the precision of material amount determination deteriorates
Solution Approach 1:
The build plane is divided into multiple build plane elements that are categorized into different categories and sub-categories based on their irradiation and consolidation requirements. This segmentation allows for differentiated material dosing strategies for different regions, improving precision while maintaining manageable complexity through systematic classification.
Solution Approach 2:
Different dosing factors are assigned to different categories and sub-categories of build plane elements based on their specific irradiation and consolidation requirements. This local quality approach ensures that each region receives the appropriate amount of build material tailored to its specific needs, thereby improving overall determination precision.
2Ease of manufacture
If static dosing factors are used, then the dosing process is straightforward, but the adaptability to different layer structures deteriorates
Solution Approach 1:
The dosing system transitions from static dosing factors to dynamic, multi-level categorization (categories and sub-categories) that adapts to different layer structures and irradiation requirements. This dynamic approach maintains ease of manufacture through automated classification while significantly improving adaptability to various additive manufacturing scenarios.
Solution Approach 2:
The system changes the dosing parameters (dosing factors) based on the category and sub-category assignments of build plane elements. By varying these parameters according to specific irradiation and consolidation requirements, the system achieves both straightforward automated dosing and high adaptability to different layer configurations.
3Device complexity
If uniform build material application is used across the build plane, then the process is simple, but the manufacturing precision of layer formation deteriorates
Solution Approach 1:
The build plane is segmented into multiple elements with different category and sub-category assignments, enabling differentiated material application across the build plane. This segmentation improves layer formation precision by tailoring material dosage to specific regional requirements while keeping the overall process manageable through systematic classification.
Solution Approach 2:
Different amounts of build material are applied to different categories and sub-categories of build plane elements based on their specific irradiation and consolidation needs. This local quality approach ensures optimal layer formation precision in each region without requiring complex manual intervention, as the differentiation is achieved through automated categorization.
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 enables individualized determination of the required build material amount for each layer, optimizing material usage and ensuring sufficient material application, even in complex layer structures.
Implementation Method 1
additively manufacturing at least one three-dimensional object by means of successive layerwise selective irradiation and consolidation of layers of build material applied in the build plane of the apparatus by means of at least one energy beam
Data Source
AI summary
Method for determining an amount of build material (3) which is to be applied in a build plane (BP) of an apparatus (1) 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 the build plane (BP) of the apparatus (1) by means of at least one energy beam (4), the method comprising the steps of: subdividing at least a part of the build plane (BP), particularly the complete build plane (BP), of the apparatus (1), in which build plane (BP) build material (3), which is to be selectively irradiated and consolidated during an additive manufacturing process of at least one three-dimensional object (2) by means of the apparatus (1), is to be applied, into a plurality of build plane elements (BPE), categorizing the build plane elements (BPE) in a first category.