Heatable Building Platform for Additive Manufacturing
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Solution Overview
Problem
In generative manufacturing methods like selective laser melting and laser metal deposition, the temperature of the building platform does not consistently match the set temperature, leading to quality issues in the component due to inadequate heat dissipation and complex heating solutions.
Innovation Solution
Equipping the building platform with a heating device that adjusts its power based on a defined reference temperature and tolerance range, using open-loop or closed-loop control to maintain a consistent temperature during the manufacturing process, and measuring surface temperature to correct heating power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heating plate is operated at a constant temperature level during the entire process, then the building platform can be kept at a desired temperature, but the temperature of the layer to be produced does not correspond to the set temperature as the component height increases
Solution Approach 1:
The heating power of the building platform is dynamically adjusted during the manufacturing process. As the component height increases and thermal accumulation occurs, the heating power is reduced to maintain the layer temperature within the reference temperature tolerance range, rather than maintaining a constant heating power throughout the process.
Solution Approach 2:
A feedback control mechanism is implemented where the actual layer temperature is monitored and compared against the reference temperature tolerance range. Based on this feedback, the heating power of the building platform is automatically adjusted to maintain temperature consistency, ensuring the layer temperature remains within acceptable limits throughout the manufacturing process.
2Stability of the object's composition
If a zone furnace is used to heat the joining zone with a predetermined temperature gradient, then the crystal structure can be influenced and controlled, but the heating system becomes technically very complex
Solution Approach 1:
The complex zone furnace system is replaced by extracting only the essential function needed - temperature control of the building platform. The building platform itself is equipped with a heating device that directly provides the necessary thermal control, eliminating the need for the complex external zone furnace infrastructure while achieving the same crystal structure control objectives.
Solution Approach 2:
The building platform serves multiple functions: it supports the component during manufacturing and simultaneously acts as the heating device through its integrated heating element. This multi-functionality eliminates the need for separate complex heating systems like zone furnaces, as the platform itself provides the necessary thermal control for crystal structure development.
3Temperature
If induction coils are provided for inductive local heating, then heat can be introduced locally into the component, but the technical complexity becomes comparatively great
Solution Approach 1:
The complex system of multiple induction coils is replaced by extracting the essential function of local heating and implementing it through the building platform's heating device. The platform can provide localized thermal control directly at the component interface without requiring external induction coils, significantly simplifying the overall heating system while maintaining local heating capability.
4Temperature
If the building platform is not heatable and is lowered into a zone furnace, then heating can be achieved, but the building platform cannot provide direct thermal control
Solution Approach 1:
The heating function is merged directly into the building platform through an integrated heating device. This combination allows the platform to provide direct thermal control to the component during manufacturing, eliminating the need to lower the platform into external heating equipment like zone furnaces. The merged system provides both support and thermal control functions in a single integrated unit.
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 simpler and more effective temperature control, reducing thermal stresses and maintaining a consistent temperature level in the component, thereby improving the quality and reducing the complexity of heating systems.
Implementation Method 1
the component under construction being heated by means of the building platform
Implementation Method 2
fused by an energy beam, for example an electron beam or a laser beam. The fusing has the effect that the particles of the building material that form the component to be manufactured are firmly held together. Fusing may take place for example by melting or sintering
Implementation Method 3
Suitable as melting methods are for example selective laser melting (also known as SLM), electron beam melting (also known as EBM) or laser metal deposition (also known as LMD)
Implementation Method 4
A temperature sensor is provided, with which closed-loop control of the supply of energy to the heating plate can be carried out
Implementation Method 5
a reference temperature Tr for the layer produced in each case and a tolerance range for the reference temperature Tr are defined and the heating power of the heating device is lowered as the method progresses to the extent that the tolerance range for a reference temperature Tr is maintained in the layer that is last produced in each case
Data Source
AI summary
Various embodiments may include a method for the generative manufacturing of a component on a building platform comprising: applying particles of a building material layer by layer to the building platform and then to the component under construction; fusing the applied particles with an energy beam; and heating the component under construction with a heating device associated with the building platform. A reference temperature Tr for each layer produced and a tolerance range for the reference temperature Tr are defined. A heating power of the heating device is lowered as sequential layers are fused to the extent that the tolerance range for a reference temperature Tr is maintained in a last layer produced.