Layered Manufacturing Depression Smoothing
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Solution Overview
Problem
Layered manufacturing methods, such as those using laser sintering, often result in deep, narrow chambers in structural components due to insufficient filling of depressions in previous layers, which are narrower than the maximum powder grain size or have projections.
Innovation Solution
A method and device that detect and smooth depressions in formed layers by measuring parameters like depth using laser or electron beams, and fill them with powder to prevent chamber formation, ensuring the smoothed depressions are wider than the maximum powder grain size and free of projections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If powder is applied to form subsequent layers, then layer formation speed is improved, but deep narrow chambers are formed due to insufficient filling of depressions
Solution Approach 1:
The depression is smoothed before the subsequent powder layer is applied. This preliminary smoothing action ensures that when powder is later applied, it can properly fill the area without forming deep narrow chambers, thus resolving the contradiction between fast layer formation and proper filling quality.
Solution Approach 2:
A smoothing element acts as an intermediary between the depression and the powder layer. This intermediary component (which could be a doctor blade, roller, or other smoothing mechanism) modifies the depression geometry before powder application, enabling both rapid production and proper filling.
2Reliability
If laser power is increased to eliminate defects, then defect elimination is improved, but energy consumption increases
Solution Approach 1:
Depressions are smoothed in advance before powder application, preventing defect formation rather than attempting to eliminate defects after they occur. This preventive approach reduces or eliminates the need for high-power laser remediation, thereby reducing energy consumption while maintaining reliability.
Solution Approach 2:
The smoothing process converts potentially harmful deep depressions that would require high-energy laser correction into beneficial shallow surfaces that naturally accept powder filling, thereby eliminating the need for energy-intensive defect elimination procedures.
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
Effectively avoids or reduces the occurrence of deep, narrow chambers in structural components by controlled smoothing and filling of depressions, ensuring efficient layer formation and preventing defects.
Implementation Method 1
the depth of the depression can be easily concluded by means of triangulation
Implementation Method 2
detecting at least one parameter of a depression in a formed layer of the structural component
Implementation Method 3
the smoothing is performed by repeated melting of the depression
Implementation Method 4
the depression is smoothed by means of a laser beam or an electron beam
Implementation Method 5
layers of powder are sintered by means of a laser
Data Source
AI summary
The invention relates to a method for the layered manufacturing of a structural component from powder, comprising the following steps: establishing at least one parameter (t) of a depression (1) in a produced layer (2) of the structural component; smoothing out the depression (1) if the at least one parameter (t) exceeds a predetermined value; and filling the smoothed-out depression (1) with powder (13).