Multi-Laser Hatching Path Planning for Defect-Free Stitching
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Solution Overview
Problem
Multi-laser additive manufacturing systems face misalignment issues, leading to surface defects such as voids and cracks in printed parts due to inconsistent melting and bonding of metal powder, caused by improper alignment of laser beams.
Innovation Solution
The system constrains laser stitching regions to locations where misalignment is tangent to the component's surface, using a computing system to determine misalignment vectors and identify optimal stitching positions, thereby minimizing or eliminating surface defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple laser devices are used to manufacture components simultaneously, then productivity increases and manufacturing time reduces, but laser misalignment occurs leading to surface defects
Solution Approach 1:
The system performs preliminary characterization of laser misalignment by determining a misalignment vector field before manufacturing. This pre-characterization allows the system to identify and avoid stitching regions where misalignment would cause surface defects, thereby maintaining high productivity while preventing quality issues through advance planning
Solution Approach 2:
The system uses feedback from the characterized misalignment vector field to dynamically adjust stitching region selection. By continuously referencing the pre-determined misalignment patterns, the system can make informed decisions about where to place stitching regions, ensuring that multiple lasers work simultaneously without creating surface defects
2Manufacturing precision
If laser beams are properly aligned to avoid surface defects, then manufacturing precision improves, but system complexity increases due to alignment constraints
Solution Approach 1:
Instead of implementing complex real-time alignment control systems, the invention performs preliminary characterization of misalignment patterns and uses this information to plan stitching regions in advance. This approach achieves high manufacturing precision by avoiding problematic areas rather than by actively correcting alignment during manufacturing, thereby reducing system complexity
Solution Approach 2:
The misalignment vector field serves as an intermediary that mediates between the physical laser misalignment and the stitching region selection. By using this computational model as an intermediary layer, the system translates complex alignment issues into simple geometric constraints for region selection, reducing the need for complex active alignment control
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 effectively reduces or eliminates surface defects by ensuring precise alignment of laser beams, enhancing the quality and consistency of additively manufactured components.
Implementation Method 1
The laser devices each generate a laser beam that melts the powder material on the build plate in and around the area where the laser beam is incident on the powder material, resulting in a melt pool
Data Source
AI summary
An additive manufacturing system and a method for manufacturing a solid component with the additive manufacturing system is provided. The method includes determining a misalignment vector field having a plurality of misalignment vectors. The method further includes identifying one or more potential stitching positions where the solid component is generally tangent to one or more misalignment vectors. The method further includes generating a plurality of first hatching paths, a plurality of second hatching paths, and one or more stitching regions. The method further includes selectively directing the first laser beam across a powder bed along the plurality of first hatching paths to consolidate a first portion of the solid component. The method further includes selectively directing the second laser beam across the powder bed along the plurality of second hatching paths to consolidate a second portion of the solid component.