Additive Manufacturing Fusing Area Density Tolerance Control
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Solution Overview
Problem
Additive manufacturing systems face quality issues due to energy absorption variances across and between build layers, leading to defects such as 'elephant skin' and thermal bleed, caused by variance in fusing area density and energy re-radiation effects, which affect the surface quality and dimensional accuracy of 3D objects.
Innovation Solution
Modifying build layers to ensure fusing area densities fall within a desired tolerance window by adjusting fusing areas and applying detailing agents, thereby harmonizing energy absorption and reducing the impact of energy re-radiation, ensuring consistent energy distribution across the build platform.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If energy is applied to solidify portions of build material layers, then the 3D object is formed, but energy absorption variances cause surface quality defects and dimensional inaccuracies
Solution Approach 1:
The patent applies local quality by selectively depositing functional agents (such as infrared absorbers or scatterers) in specific regions of the build material layers where energy absorption variances occur. This targeted approach modifies the energy absorption properties only in the affected areas, ensuring uniform energy distribution and eliminating surface defects like 'elephant skin' and thermal bleed while maintaining the overall manufacturing process integrity.
Solution Approach 2:
The patent changes physical parameters of the build material by incorporating functional agents that alter the energy absorption characteristics. By modifying the infrared absorption coefficient and scattering properties of the build material in specific regions, the system achieves uniform energy distribution across layers, thereby improving dimensional accuracy and surface quality without changing the fundamental additive manufacturing process.
2Manufacturing precision
If functional agents are selectively deposited to control solidification portions, then solidification is precisely controlled, but surface quality defects such as 'elephant skin' and thermal bleed occur due to energy re-radiation effects
Solution Approach 1:
The patent introduces functional agents as intermediary substances that mediate between the applied energy and the build material. These agents (such as infrared absorbers or scatterers) act as intermediaries to distribute energy more uniformly, preventing excessive energy concentration that causes thermal bleed and 'elephant skin' defects, while still allowing precise solidification control through selective deposition.
Solution Approach 2:
The patent converts the harmful energy re-radiation effect into a beneficial distribution mechanism by using functional agents that scatter and redistribute infrared energy. The re-radiation that would normally cause surface defects is transformed into a uniform energy distribution pattern, improving surface quality while maintaining the necessary thermal energy for solidification.
3Manufacturing precision
If build layers are processed to ensure uniform fusing area density, then energy distribution is harmonized, but additional processing steps and detailing agents are required
Solution Approach 1:
The patent merges the functional agent deposition step with the existing selective deposition process. By using the same deposition mechanism to apply both structural material and functional agents, the system achieves uniform energy distribution without adding separate processing equipment or complex additional steps, thereby minimizing the increase in device complexity.
Solution Approach 2:
The patent makes the deposition system multi-functional by enabling it to deposit both build material and functional agents using the same apparatus. This universal approach allows a single system to perform multiple functions (structural deposition and energy distribution optimization) without requiring separate specialized equipment, thus limiting the increase in processing complexity.
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 surface uniformity, dimensional accuracy, and reduces defects in 3D objects by homogenizing energy absorption, leading to better part quality and productivity.
Implementation Method 1
energy absorption variances across and between build layers
Implementation Method 2
energy re-radiation effects
Data Source
AI summary
In certain examples, a method comprises determining a fusing area density distribution of a build layer from build data relating to a build layer of a three-dimensional model to be printed by an additive manufacturing system. The method comprises, in response to a determination that a region of the build layer has a fusing area density outside of a fusing area density tolerance window, modifying the build layer to define a build layer in which the region has a fusing area density that is within the fusing area density tolerance window.