3D Object Irradiation by Geometry-Based Region Parameters
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Solution Overview
Problem
Existing additive manufacturing techniques face challenges in efficiently irradiating complex three-dimensional objects with varying geometries, often requiring a compromise between writing speed and resolution, leading to increased writing time due to uniform irradiation parameters across different regions.
Innovation Solution
A method that assigns specific irradiation parameters to different regions of a three-dimensional object based on geometry information, allowing for tailored irradiation processes using varying spot sizes and intensities, thereby optimizing the irradiation of both fine details and larger structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If uniform irradiation parameters are used across all regions, then the irradiation process is simplified, but writing time increases due to inability to optimize for different geometrical regions
Solution Approach 1:
The build platform area is divided into multiple regions based on geometrical characteristics (e.g., regions with fine details versus regions with larger structures). Each region is assigned specific irradiation parameters tailored to its geometrical requirements, allowing optimized writing speed for each region type while maintaining overall process simplicity through automated region-based parameter assignment.
2Manufacturing precision
If lower intensity irradiation parameters are used, then resolution of geometrical details is improved, but writing time increases for larger areas
Solution Approach 1:
Different irradiation parameters (intensity, spot size, scanning speed) are assigned to different regions based on their geometrical characteristics. Regions containing fine geometrical details receive lower intensity and smaller spot sizes to ensure high resolution, while regions with larger structures receive higher intensity and larger spot sizes to maintain fast writing speed. This local optimization eliminates the need to use uniform conservative parameters across the entire build area.
3Productivity
If higher intensity irradiation parameters are used, then writing speed is improved for larger areas, but resolution of fine geometrical details deteriorates
Solution Approach 1:
The build area is segmented into regions requiring high resolution (fine details) and regions allowing high speed (larger structures). By separating the irradiation process into region-specific parameter sets, the system can apply high intensity parameters to appropriate regions without compromising the resolution of delicate features in other regions, thus achieving overall productivity improvement without sacrificing precision where needed.
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 reduces writing time and ensures proper irradiation of geometrical details by allowing for faster processing of larger areas while maintaining high resolution in delicate features, eliminating the need for uniform irradiation parameters.
Implementation Method 1
successive layerwise selective irradiation and consolidation of layers of a build material which can be consolidated by means of an energy source
Implementation Method 2
irradiation data define at least two regions of object data relating to a three-dimensional object, which regions are irradiated based on at least two different irradiation parameters
Data Source
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Figure 2
AI summary
Method for operating an apparatus (1) for additively manufacturing three-dimensional objects (2) by means of successive layerwise selective irradiation and consolidation of layers of a build material (3) which can be consolidated by means of an energy source, wherein irradiation data define at least two regions (8, 9) of object data relating to a three-dimensional object (2), which regions (8, 9) are irradiated based on at least two different irradiation parameters, wherein at least one first irradiation parameter is assigned to at least one first region (8) and at least one second irradiation parameter is assigned to at least one second region (9) based on a geometry information of the first region (8) and the second region (9) at least one first region (8) is irradiated based on at least one first irradiation parameter and at least one second region (9) is irradiated based on at least one second irradiation parameter based on a geometry information of the first region (8) and the second region (9).