Energy Beam Surface Smoothing for 3D Build Objects

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Solution Overview

Problem

Existing build apparatuses face challenges in effectively processing and smoothing the surface of three-dimensional structural objects formed by Laser Metal Deposition, particularly in addressing irregularities and ensuring proper irradiation of energy beams to achieve uniform surface finishing.

Innovation Solution

A processing apparatus and method that utilize an energy beam irradiation system with a position change apparatus and attitude adjustment mechanism, controlled by shape information, to precisely irradiate and process the surface of build objects, ensuring optimal energy distribution and surface smoothing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a build apparatus forms a build object by melting powdery material with an energy beam, then the three-dimensional structural object can be created, but the surface of the build object becomes rough and irregular due to adhered powdery material and improper surface processing

Engineering Contradiction:

Improvesurface finishing qualityVSAvoidsurface processing difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by performing surface processing operations on the build object immediately after formation while the object is still in the build apparatus. The energy beam irradiation and powder removal processes are conducted in-situ before the object is removed, preventing surface irregularities from setting and eliminating the need for separate post-processing steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The build apparatus is designed with multi-functionality, serving both as a formation device and a surface processing device. The same energy beam system used to melt and form the build object is also used to process and smooth the surface, while integrated powder removal mechanisms handle both excess powder during formation and adhered powder on the surface.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If the energy beam irradiation position is not precisely controlled, then the surface processing is inefficient, but precise positioning requires complex control systems and shape information processing

Engineering Contradiction:

Improvesurface processing efficiencyVSAvoidcontrol system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent implements feedback control by continuously monitoring the build object's shape information and using this data to dynamically adjust the energy beam irradiation position. The control system receives shape data, processes it to determine optimal irradiation locations, and adjusts the beam positioning in real-time, creating a closed-loop system that improves efficiency without requiring overly complex manual control mechanisms.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces complex mechanical positioning systems with computer-controlled beam steering and shape information-based positioning. Instead of using complex mechanical devices to physically move processing components, the system uses digital shape information to control the energy beam's irradiation positions, substituting mechanical complexity with computational control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If the energy beam irradiates all surfaces of the build object, then complete surface processing is achieved, but the irradiation time and energy consumption increase significantly

Engineering Contradiction:

Improvesurface processing completenessVSAvoidprocessing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent applies local quality by selectively irradiating only specific regions of the build object's surface that require processing. Instead of uniformly treating all surfaces, the system identifies and processes only the areas with adhered powder or surface irregularities, leaving already-smooth areas untouched. This localized approach maintains surface processing completeness while significantly reducing the total irradiation time and energy consumption.

Inventive Principle:

Principle #3Local quality

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 solution enables precise control over energy beam positioning and attitude adjustment, resulting in improved surface smoothing and finishing of three-dimensional structural objects, addressing irregularities and enhancing the quality of the final product.

Implementation Method 1

an energy beam irradiation apparatus that irradiates at least a part of a surface of the object with the energy beam

Methodology Applied

Scientific EffectLaser heating: Laser

Data Source

PatentUS20210178521A1Processing apparatus, processing method, machining method, modeling apparatus, modeling method, computer program and recording medium

Publication Date: 2021.06.17 NIKON CORP

AI summary

A processing apparatus is a processing apparatus that performs a process for irradiating an object with an energy beam, the processing apparatus is provided with: an energy beam irradiation apparatus that irradiates at least a part of a surface of the object with the energy beam; and a position change apparatus that changes an irradiation position of the energy beam at the surface of the object, the processing apparatus controls the irradiation position of the energy beam by using a shape information relating to a shape of the object.