Dual Beam Additive Manufacturing for Large Build Volume
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Solution Overview
Problem
Existing additive manufacturing techniques face challenges in building larger three-dimensional articles without compromising the quality of the energy beam spot, particularly due to increased build volume requirements that necessitate higher beam power and deflection angles, leading to process difficulties.
Innovation Solution
The method employs two energy beam sources to fuse powder layers, with overlapping zones where the beams' power is adjusted to maintain a constant sum, ensuring consistent beam quality by varying the power of one beam from 100% to 0% and the other from 0% to 100% across the overlapping zone, and simultaneously fusing areas using both beams to maintain the desired power level.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If higher beam power and deflection angles are used to increase build volume, then larger three-dimensional articles can be produced, but beam spot quality deteriorates due to process difficulties
Solution Approach 1:
The patent divides the build area into multiple overlapping zones covered by different beam sources. Each beam source operates independently with optimized parameters for its specific zone, allowing the system to maintain high beam spot quality in each local area while collectively covering a large build volume. The overlapping zones ensure continuous coverage and consistent quality across the entire build area.
2Manufacturing precision
If a single energy beam source is used to maintain beam spot quality, then manufacturing precision is preserved, but build volume is limited due to higher beam power requirements
Solution Approach 1:
The patent combines multiple energy beam sources to work simultaneously on different zones of the powder bed. By merging the capabilities of multiple beams with optimized individual parameters, the system achieves both high manufacturing precision in each zone and large overall build volume. The coordinated operation of multiple beams allows coverage of areas that would require excessive power from a single beam source.
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 larger build volumes with maintained beam spot quality, as the combined power of the beams in overlapping zones is kept constant, preventing power imbalances and ensuring consistent fusion across the build area.
Implementation Method 1
directing a first energy beam from a first energy beam source over a work table, wherein the directing of the first energy beam causes a first powder layer to fuse in first selected locations according to the model
Implementation Method 2
directing a second energy beam from a second energy beam source over the work table, wherein the directing of the second energy beam causes the first powder layer to fuse in second selected locations according to the model
Implementation Method 3
maintaining the sum of power of the first and second beam in the first overlapping zone at a predetermined value
Data Source
Figure 1a~1c
Figure 2
Figure 3
AI summary
A method for forming a three-dimensional article through successive fusion of parts of a powder bed, which parts corresponds to successive cross sections of the three-dimensional article, said method comprising the steps of: providing a model of said three dimensional article, providing a first powder layer on a work table, directing a first energy beam from a first energy beam source over said work table causing said first powder layer to fuse in first selected locations according to said model to form a first cross section of said three-dimensional article, directing a second energy beam from a second energy beam source over said work table causing said first powder layer to fuse in second selected locations according to said model to form the first cross section of said three-dimensional article, wherein said first and second locations of said first powder layer are at least partially overlapping each other.