Contour Stitching Hooks for Additive Manufacturing Misalignment
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Solution Overview
Problem
Additive manufacturing systems face misalignment issues during the manufacturing process, leading to roughness and sharpness on the contours of components due to laser beam misalignment, which existing methods struggle to effectively address.
Innovation Solution
The implementation of hooks at the end of contour paths in additive manufacturing systems, which are configured to extend into hatching paths at an angle, stitching together misaligned contour paths and reducing surface roughness and sharpness by creating a sloped transition between them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple laser beams are used to manufacture components simultaneously, then manufacturing time is reduced and productivity increases, but laser beam misalignment occurs causing contour roughness and sharpness
Solution Approach 1:
The system performs preliminary alignment checks and adjustments before each contour stitching operation. The control system proactively identifies potential misalignment issues and corrects them in advance, preventing contour roughness before it occurs during the manufacturing process
Solution Approach 2:
The system incorporates real-time feedback mechanisms that monitor laser beam position and contour quality during manufacturing. When misalignment is detected, the control system automatically adjusts beam positioning to maintain contour smoothness, creating a closed-loop control system that resolves the contradiction between productivity and precision
2Manufacturing precision
If laser beams are calibrated before the manufacturing process, then initial alignment is ensured, but misalignment develops during the process causing steps and sharp corners on contours
Solution Approach 1:
The system transitions from static pre-calibration to dynamic real-time alignment. The control system continuously monitors and adjusts laser beam positioning during the manufacturing process, allowing the system to adapt to thermal drift, mechanical expansion, and other dynamic factors that cause misalignment and maintain contour continuity throughout production
Solution Approach 2:
The system performs preliminary alignment checks and adjustments before each contour stitching operation. The control system proactively identifies potential misalignment issues and corrects them in advance, preventing contour roughness before it occurs during the manufacturing process
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 use of hooks effectively reduces the roughness and sharpness of the component's surface by aligning misaligned contour paths, enhancing the smoothness and continuity of the component's outer surface.
Implementation Method 1
The laser devices each generate a laser beam that melts the powder material on the build platform in and around the area where the laser beam is incident on the powder material, resulting in a melt pool
Implementation Method 2
The laser beams melt the powder material on the build platform, resulting in a melt pool that cools into a consolidated, solid top layer
Implementation Method 3
The melt pool cools into a consolidated, solid top layer of the component
Data Source
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AI summary
An additive manufacturing system (10) includes a first laser device (14) configured to generate a first laser beam (16) and a second laser device (15) configured to generate a second laser beam (17). The laser scanning devices (18, 19) include a first laser scanning device (18) and a second laser scanning device (19). The first laser scanning device (18) is configured to selectively direct the first laser beam (16) from the first laser device (14)s (14, 15) across a powder bed (21) along a plurality of first hatching paths (206) and a first contour path (208) along a contour of the solid component (28). The second laser scanning device (19) is configured to selectively direct the second laser beam (17) from the second laser device (15)s (14, 15) across the powder bed (21) along a plurality of second hatching paths (210) and a second contour path (212) along the contour of the solid component (28). The first contour path (208) includes a first hook (402) extending into the plurality of second hatching paths (210).