Fiber Array Multi-Beam Additive Manufacturing for Lower Thermal Stress
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Solution Overview
Problem
Laser additive manufacturing techniques face challenges with slow build rates and thermal stresses, particularly when using superalloys and larger powder particle sizes, due to the limitations of single beam systems in delivering sufficient power and causing excessive thermal stress.
Innovation Solution
A multiple beam additive manufacturing method that uses an array of light sources and optical fibers to simultaneously direct multiple beams to different regions of a powder layer, creating distributed exposures with spaced beam spots to fuse the material efficiently, reducing thermal stresses and increasing build speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple beams are scanned across the powder layers to increase build rate, then productivity is improved, but thermal stress increases causing deformation and cracking
Solution Approach 1:
The patent divides the single laser beam into multiple separate beams that scan different regions of the powder layer simultaneously. This segmentation allows the thermal energy to be distributed across multiple locations rather than concentrated in one area, reducing cumulative thermal stress while maintaining high build rates through parallel processing of multiple voxels.
2Productivity
If laser power is increased to achieve faster build rates, then productivity is improved, but thermal stress increases causing cracking in superalloys
Solution Approach 1:
Instead of using one high-power laser beam that concentrates thermal energy, the patent segments the power delivery across multiple lower-power beams. Each beam delivers sufficient energy to fuse individual voxels, but the distributed nature of multiple beams prevents excessive thermal accumulation and stress concentration that would cause cracking in heat-sensitive materials like superalloys.
3Adaptability or versatility
If single beam laser power is increased to melt larger powder particles, then adaptability is improved, but thermal stress increases causing deformation
Solution Approach 1:
The patent enables processing of larger powder particles by distributing the melting action across multiple beams that can simultaneously target different particles. This segmentation allows each beam to work on smaller individual particles without requiring excessive power concentration, thereby melting larger particles effectively while avoiding the thermal stress and deformation associated with high-power single-beam processing.
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 faster build rates while minimizing thermal stresses, enabling the use of a wide range of materials including superalloys and larger powder sizes, and improving the quality and speed of three-dimensional structure formation.
Implementation Method 1
using a light beam (e.g., laser light) to bind or fuse the powder material in selected regions of each layer
Implementation Method 2
The thermal energy, for example, may cause thermal part stress, which may deform the three-dimensional structure
Data Source
Figure 1
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Figure 4A~4D
AI summary
Systems and methods for multiple beam additive manufacturing use multiple beams of light (e.g., laser light) simultaneously to expose layers of powder material in selected regions until the powder material fuses to form voxels, which form build layers of a three-dimensional structure. The light may be generated from selected light sources and coupled into an array of optical fibers having output ends arranged in an optical head such that the multiple beams are directed by the optical head to different locations on each of the powder layers. The multiple beams may provide distributed exposures forming a distributed exposure pattern including beam spots that are spaced sufficiently to separate the fused regions formed by each exposure. The multiple beams may be moved using various techniques (e.g., by moving the optical head) and according to various scan patterns such that a plurality of multiple beam distributed exposures form each build layer.