Galvanometric Head Sintering Zone Extension
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Solution Overview
Problem
Existing laser sintering technologies face limitations in achieving uniform treatment across the maximum sintering zone due to restricted size and non-homogeneous irradiation, resulting in suboptimal quality and capacity for manufacturing three-dimensional objects.
Innovation Solution
The solution involves extending the overall sintering zone by dividing it into effective sintering zones, which are positioned and controlled to ensure homogeneous treatment, using a combination of beam deflection and focusing mechanisms, including a 'third axis' device and flat field lens, to maximize reflectivity and minimize variations in irradiation intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If mirrors mounted on galvanometers are used for beam deflection, then the device can achieve beam shaping and deflection, but the maximum sintering area is limited due to restricted angular displacement of the mirrors
Solution Approach 1:
The patent divides the maximum sintering zone into multiple effective sintering zones, each corresponding to a specific angular position of the mirrors. By segmenting the total area into smaller zones that can be uniformly treated by the limited mirror displacement, the system overcomes the restriction of small angular ranges while achieving coverage of a larger overall area through sequential processing of each zone.
2Manufacturing precision
If mirrors with limited angular displacement are used, then the device structure is simpler, but the reflection coefficient varies significantly with angle of incidence, causing non-homogeneous irradiation
Solution Approach 1:
The patent applies local quality by optimizing the mirror angular positions for each effective sintering zone to maintain reflection coefficients above 99%. Each zone is treated with locally optimized beam parameters and mirror angles that ensure homogeneous irradiation distribution within that specific zone, compensating for the angle-dependent reflection variations.
3Area of stationary object
If a flat field lens is used for focusing, then the beam can be focused in the sintering plane, but the sintering area is further restricted and beam radius varies across the field
Solution Approach 1:
The patent employs dynamic focusing by moving the lens along the optical axis to adjust the focal position for different effective sintering zones. This dynamic adjustment compensates for the field-dependent beam radius variations inherent in flat field lenses, maintaining uniform beam characteristics across each zone while enabling coverage of a larger overall area through sequential zone 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 enables uniform and efficient treatment across a larger sintering area, reducing reflection losses and maintaining high irradiation intensity, thereby improving the quality and capacity for manufacturing three-dimensional objects.
Implementation Method 1
an electromagnetic radiation source or laser source capable of emitting a laser beam
Implementation Method 2
The layer of powdered or liquid material is progressively solidified by applying a laser beam
Implementation Method 3
solidification by laser beam of a layer of a powdery or liquid material
Implementation Method 4
beam deflection methods include, for example, mirrors mounted on galvanometers... the reflection coefficient on the mirrors varies depending on the angle of incidence of the laser beam
Implementation Method 5
a flat field lens placed downstream of the beam deflection means... a device operating a change in focal length placed upstream of the beam deflection means
Data Source
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AI summary
The invention relates to a device for the manufacture of three-dimensional objects using superimposed layers which is capable, for each layer that is to be manufactured, of applying a laser beam treatment to a layer of a pulverulent material or liquid placed in a sintering field, said device comprising a galvanometric head (12) able to steer a laser beam toward each point of a maximum sintering zone of said sintering field when said galvanometric head (12) is positioned at a predetermined position. The device further comprises limiting means (34) able to limit the steering of the laser beam to an effective sintering zone situated inside said maximum sintering zone, and movement means (30) for moving said galvanometric head (12) in a plane parallel to the plane of said sintering field, allowing said galvanometric head (12) to be positioned at at least two different positions, an effective sintering zone being associated with each position of said galvanometric head. The invention also relates to an associated method of manufacturing three-dimensional objects.