Energy-Beam Melt Pooling for Low-Porosity 3D Print Layers
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Solution Overview
Problem
Current additive manufacturing methods face challenges in achieving strong adhesion and reduced porosity between layers, leading to suboptimal mechanical, thermal, and electrical properties of 3D printed objects due to the deposition of layers below their melting temperature.
Innovation Solution
The method involves creating a 'melt pool' in the current layer using an energy source like a laser or hot fluid before depositing the next layer, which increases diffusion and mixing between layers, enhancing chemical bonding and reducing void space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If layers are deposited in conventional additive manufacturing without pre-heating, then the printing process is faster and simpler, but interlayer adhesion is weak and porosity is high
Solution Approach 1:
The patent applies preliminary action by pre-heating the build plate and deposited layers to near-melting temperatures before new material is deposited. This pre-heating prepares the surface in advance to receive the new layer, ensuring strong interlayer adhesion and reduced porosity from the start of each layer deposition, rather than attempting to achieve bonding after the fact.
Solution Approach 2:
The patent fundamentally changes the temperature parameter of the build plate and deposited layers from conventional room temperature or mild heating to high temperatures approaching the melting point of the material. This parameter change transforms the physical state of the material surface, enabling superior bonding and densification while maintaining printing efficiency through automated temperature control.
2Manufacturing precision
If layers are deposited below melting temperature, then the printing process is simpler and faster, but porosity increases and mechanical properties deteriorate
Solution Approach 1:
The build plate is designed to serve multiple functions: it acts as the substrate for depositing layers, as a heating element to pre-heat deposited material, and as a thermal management system to control the temperature of subsequent layers. This multi-functionality reduces the need for separate heating apparatus and simplifies the overall system while achieving superior layer bonding and reduced porosity.
3Reliability
If energy beam is used to melt layers, then interlayer bonding and density improve, but energy consumption increases
Solution Approach 1:
The build plate performs preliminary heating of deposited layers to near-melting temperatures before the energy beam arrives. This pre-heating reduces the amount of energy the beam must supply to achieve melting and bonding, thereby improving part density while reducing overall energy consumption. The beam only needs to provide the final melting energy rather than heating from a lower temperature.
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 improves the mechanical, thermal, and electrical properties of 3D printed objects by increasing adhesion in the Z-direction and reducing porosity, resulting in higher quality parts with enhanced interlayer bonding.
Implementation Method 1
using at least a first energy beam from at least one energy source to selectively melt at least a portion of the first layer and/or the second layer
Implementation Method 2
at least one energy source to selectively melt at least a portion of the first layer and/or the second layer
Implementation Method 3
which increases diffusion and mixing between layers, enhancing chemical bonding and reducing void space
Data Source
AI summary
The present disclosure provides methods for printing at least a portion of a three-dimensional (3D) object, comprising receiving, in computer memory, a model of the 3D object. Next, at least one filament material from a source of the at least one filament material may be directed towards a substrate that is configured to support the 3D object, thereby depositing a first layer corresponding to a portion of the 3D object adjacent to the substrate. A second layer corresponding to at least a portion of the 3D object may be deposited. The first and second layer may be deposited in accordance with the model of the 3D object. At least a first energy beam from at least one energy source may be used to selectively melt at least a portion of the first layer and/or the second layer, thereby forming at least a portion of the 3D object.